Article of footwear comprising a sole member with geometric patterns

ABSTRACT

An article of footwear includes an upper and a sole structure with a sole member. The sole member can include a set of apertures that is formed along various surfaces of the sole member. The sole member can be manufactured using a customized cushioning sole system, forming generally circular patterns throughout the sole member. A user&#39;s foot morphology and/or preferences may be used to design the sole member.

RELATED APPLICATION DATA

This application is a divisional application based on co-pending U.S.patent application Ser. No. 14/722,826 titled “Article of FootwearComprising a Sole Member with Geometric Patterns,” filed May 27, 2015.U.S. patent application Ser. No. 14/722,826 is entirely incorporatedherein by reference.

BACKGROUND

The present embodiments relate generally to articles of footwear, and inparticular to articles with cushioning provisions and methods of makingsuch articles.

Articles of footwear generally include two primary elements: an upperand a sole structure. The upper is often formed from a plurality ofmaterial elements (e.g., textiles, polymer sheet layers, foam layers,leather, synthetic leather) that are stitched or adhesively bondedtogether to form a void on the interior of the footwear for comfortablyand securely receiving a foot. More particularly, the upper forms astructure that extends over instep and toe areas of the foot, alongmedial and lateral sides of the foot, and around a heel area of thefoot. The upper may also incorporate a lacing system to adjust the fitof the footwear, as well as permitting entry and removal of the footfrom the void within the upper. In addition, the upper may include atongue that extends under the lacing system to enhance the adjustabilityand comfort of the footwear, and the upper may incorporate a heelcounter.

The sole structure is secured to a lower portion of the upper so as tobe positioned between the foot and the ground. In athletic footwear, forexample, the sole structure includes a midsole and an outsole. Thevarious sole structure components may be formed from a polymer foammaterial that attenuates ground reaction forces (i.e., providescushioning) during walking, running, and other ambulatory activities.The sole structure may also include fluid-filled chambers, plates,moderators, or other elements that further attenuate forces, enhancestability, or influence the motions of the foot, for example.

SUMMARY

In one aspect, the present disclosure is directed to a sole member foran article of footwear, comprising the sole member, the sole memberincluding an outer surface, and the outer surface comprising an uppersurface and a lower surface. Furthermore, the sole member has aninterior portion, where the interior portion is disposed between theupper surface and the lower surface. The sole member includes at least afirst set of apertures, where at least one of the apertures of the firstset of apertures is a blind-hole aperture. The first set of apertures isdisposed along a portion of the outer surface of the sole member, andeach aperture of the first set of apertures has a length extendingthrough a portion of the interior portion of the sole member. The firstset of apertures is arranged along the outer surface of the sole memberin a generally circular first pattern.

In another aspect, the present disclosure is directed to a sole memberfor an article of footwear, comprising the sole member, the sole memberincluding an outer surface, and the outer surface comprising an uppersurface and a lower surface. The sole member has at least a first set ofapertures, where at least one of the first set of apertures is ablind-hole aperture. The first set of apertures is disposed along aportion of the outer surface of the sole member to form a generallycircular first pattern, and each aperture of the first set of aperturesis disposed at a first radial distance from a center of the firstpattern.

In another aspect, the present disclosure is directed to a method forcustomizing a cushioning sole system for an article of footwear, themethod comprising obtaining information about a pressure distribution ofa wearer's foot, and producing a first pattern comprising a first set ofapertures disposed around a center of the first pattern. The methodfurther includes generating instructions to form the first pattern in asole member, and executing the instructions to form the first set ofapertures in the sole member, wherein each aperture of the first set ofapertures is disposed at a first radial distance from the center.

Other systems, methods, features, and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features, andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is an isometric view of an embodiment of a cushioning elementincluding apertures;

FIG. 2 is an isometric view of an embodiment of a cushioning elementincluding apertures;

FIG. 3 is an isometric view of an embodiment of a cushioning elementincluding apertures;

FIG. 4 is an isometric bottom view of an embodiment of a sole membercomprising a cushioning element;

FIG. 5 is an isometric view of an embodiment of a cushioning elementincluding apertures in an unloaded state;

FIG. 6 is an isometric view of an embodiment of a cushioning elementincluding apertures experiencing deformation;

FIG. 7 is an isometric bottom view of an embodiment of a sole membercomprising a cushioning element;

FIG. 8 is an isometric view of an embodiment of a cushioning elementincluding apertures in an unloaded state;

FIG. 9 is an isometric view of an embodiment of a cushioning elementincluding apertures experiencing deformation;

FIG. 10 is an isometric view of an embodiment of an aperture pattern;

FIG. 11 is an isometric view of an embodiment of an aperture pattern;

FIG. 12 is an isometric view of an embodiment of an aperture pattern;

FIG. 13 is an isometric view of an embodiment of an aperture pattern;

FIG. 14 is an isometric view of an embodiment of an aperture pattern;

FIG. 15 is an isometric view of an embodiment of an aperture pattern;

FIG. 16 is an isometric view of an embodiment of an aperture pattern;

FIG. 17 is an isometric view of an embodiment of an aperture pattern;

FIG. 18 is an isometric view of an embodiment of an aperture pattern;

FIG. 19 is an isometric view of an embodiment of an aperture pattern;

FIG. 20 illustrates an embodiment of the use of a device for obtainingthree-dimensional foot data;

FIG. 21 schematically illustrates an embodiment of a virtual image ofdigitized three-dimensional foot data;

FIG. 22 schematically illustrates an embodiment of a virtual image of atemplate for a sole structure;

FIG. 23 schematically illustrates an embodiment of a virtual image of acustomized sole structure;

FIG. 24 is an isometric view of an embodiment of a sole member during aprocess of forming apertures;

FIG. 25 is an embodiment of an influence diagram;

FIG. 26 is an isometric bottom view of an embodiment of an article offootwear with a sole member; and

FIG. 27 is an embodiment of a flow chart for a method of making a customsole member.

DETAILED DESCRIPTION

FIGS. 1-3 depict different embodiments of a portion of a cushioningelement. A cushioning element can include provisions for increasingflexibility, fit, comfort, and/or stability during deformation or use ofthe cushioning element or article incorporating the cushioning element.Some of the embodiments of cushioning elements as disclosed herein maybe utilized in various articles of apparel. In one embodiment, thecushioning elements may be used in an article of footwear. For example,as discussed in further detail below, in one embodiment, portions of asole structure or sole member may incorporate or otherwise include acushioning element.

For consistency and convenience, directional adjectives are alsoemployed throughout this detailed description corresponding to theillustrated embodiments. The term “lateral” or “lateral direction” asused throughout this detailed description and in the claims refers to adirection extending along a width of a component or element. Forexample, a lateral direction may be oriented along a lateral axis 190 ofa foot (see FIG. 20), which axis may extend between a medial side and alateral side of the foot. Additionally, the term “longitudinal” or“longitudinal direction” as used throughout this detailed descriptionand in the claims refers to a direction extending across a length of anelement or component (such as a sole member). For example, alongitudinal direction may be oriented along a longitudinal axis 180,which axis may extend from a forefoot region to a heel region of a foot(see FIG. 20). It will be understood that each of these directionaladjectives may also be applied to individual components of an article offootwear, such as an upper and/or a sole member. In addition, a verticalaxis 170 refers to the axis perpendicular to a horizontal surfacedefined by longitudinal axis 180 and lateral axis 190.

FIG. 1 depicts an embodiment of a first cushioning element (“firstelement”) 100, FIG. 2 depicts an embodiment of a second cushioningelement (“second element”) 200, and FIG. 3 depicts an embodiment of athird cushioning element (“third element”) 300. As shown in FIGS. 1-3,in some embodiments, a cushioning element can include one or moreapertures 150. For purposes of this description, apertures 150 areopenings, apertures, holes, tunnels, or spaces that are disposed withinthe cushioning element. Generally, apertures 150 are initially formedalong an exterior or outer surface of the cushioning element, and canextend any distance, and along any orientation, through an interiorportion 199 (e.g., the thickness, breadth, or width) of the cushioningelement. It should be understood that the terms exterior or outersurface with reference to a sole member does not necessarily indicatewhether the sole member is actually exposed to the outer elements.Instead, outer surface or exterior surface refers to the outermost,outward-facing layer of the sole member. Interior portion 199 can bedisposed between upper surface 152, lower surface 154, and a sidewall insome embodiments. Throughout the specification, it should be understoodthat characteristics being described as associated with a singleaperture or aperture set can also characterize any other aperture oraperture set that may be referred to in the various embodiments.

The embodiments described herein may also include or refer totechniques, concepts, features, elements, methods, and/or componentsfrom: (a) U.S. patent application Ser. No. 14/722,758, filed May 27,2015, titled “Article of Footwear Comprising a Sole Member withApertures;” (b) U.S. patent application Ser. No. 14/722,782, filed May27, 2015, titled “Article of Footwear Comprising a Sole Member withAperture Patterns;” and (c) U.S. patent application Ser. No. 14/722,740,filed May 27, 2015, titled “Article of Footwear Comprising a Sole Memberwith Regional Patterns,” the entirety of each application being hereinincorporated by reference.

In different embodiments, cushioning elements may comprise anythree-dimensional shape or geometry, including regular or irregularshapes. For example, cushioning elements may be substantially flat ornarrow, and/or relatively thick or wide. The geometry and dimensions ofa cushioning element can be configured for the application or exercisein which it will be used. For illustrative purposes, in FIGS. 1-3, theportions of cushioning elements have a generally oblong rectangularthree-dimensional shape. Furthermore, for purposes of reference, asshown in FIGS. 1-3, each cushioning element may include upper surface152 and lower surface 154 that is disposed opposite of upper surface152. In some cases, upper surface 152 can be disposed adjacent to orjoined to another component, such as an upper (see FIG. 26). Inaddition, in some cases, lower surface 154 can be a ground-contactingsurface. However, in other cases, lower surface 154 may be disposedadjacent to another material (such as an outsole). The cushioningelements can further include additional exterior-facing surfaces. Forexample, as shown in FIGS. 1-3, the cushioning elements have foursidewalls, including first side 156, second side 157, third side 158,and fourth side 159. First side 156, second side 157, third side 158,and fourth side 159 may extend between upper surface 152 and lowersurface 154. In addition, cushioning elements include thickness 140extending between upper surface 152 and lower surface 154 along verticalaxis 170, and width 146 extending from second side 157 to fourth side159 along lateral axis 190, as well as length 148 extending alonglongitudinal axis 180 from first side 156 to third side 158. As noted inFIG. 1, thickness 140 may include upper portion 182 and lower portion184. Width 146 may include forward portion 192 and rear portion 194.Furthermore, length 148 may include first side portion 186 and secondside portion 188. Upper surface 152, lower surface 154, and sidewalls asdepicted herein are associated with an outer surface of the cushioningelements.

It should be understood that other embodiments can have a fewer orgreater number of exterior surfaces, and that the cushioning elementsand the different regions of cushioning elements shown herein are forillustrative purposes only. In other embodiments, cushioning elementsmay include any contour, and may be any size, shape, thickness, ordimension, including regular and irregular shapes.

In some embodiments, apertures 150 have a rounded shape. In otherembodiments, apertures 150 may include a wide variety of othergeometries, including regular and irregular shapes. Apertures 150 mayhave a cross-sectional shape that is round, square, or triangular, forexample. In some embodiments, apertures 150 may have a variety ofgeometric shapes that may be chosen to impart specific aesthetic orfunctional properties to a cushioning element. In one embodiment,apertures 150 may comprise a void that has a substantially cylindricalshape. In some embodiments, the cross-sectional diameter of the aperturemay be substantially consistent or uniform throughout the length of theaperture.

In some cases, apertures 150 can be provided on or through lower surface154 or upper surface 152 of the cushioning element. In other cases,apertures 150 can be provided on or through a side surface of thecushioning element. In one embodiment, apertures 150 can be provided onor through the side surfaces (for example, along first side 156, secondside 157, third side 158, and/or fourth side 159) of the cushioningelement as well as on lower surface 154 and upper surface 152 of thecushioning element.

In some embodiments, apertures 150 can provide means for decoupling orsoftening portions of a cushioning element in order to enhance itscushioning characteristics. For purposes of this disclosure, cushioningcharacteristics refer to the degree of fit, flexibility, cushioning,responsiveness, comfort, resilience, shock absorption, elasticity,and/or stability present in a portion of an element. For example, insome cases, apertures 150 can be formed in side portions and a lowerportion of a cushioning element to reduce the cross-sectional profile ofthe element at particular regions and/or to facilitate increasedflexibility between various portions of the element. In one embodiment,apertures 150 can be applied to side portions and an upper portion toform regions between adjacent portions of the element that articulate orbend with respect to one another.

Thus, in the present embodiments, the operation of the cushioningelements can involve providing a material variance in the element. Thematerial variance can be accomplished by providing voids (apertures)that can comprise cut-outs through the cushioning element. As will bedescribed below with respect to FIG. 25, the cut-outs can involve aremoval of material from the element, thereby providing softer and/orcushioned regions in the portions that include the apertures.

Generally, apertures 150 can comprise various openings or holes arrangedin a variety of orientations and in a variety of locations on or throughthe cushioning element. For example, as shown in FIG. 1, in someembodiments, a first aperture set 102 may include apertures 150 thatextend in a direction generally aligned with vertical axis 170 throughthickness 140 of first element 100. In first cutaway section 104 offirst element 100 of FIG. 1, it can be seen that the apertures of firstaperture set 102 begin along lower surface 154 and extend toward uppersurface 152. Thus, apertures 150 of first aperture set 102 include aseries of openings 142 (i.e., gaps or openings) along an exteriorsurface of first element 100. In FIG. 1, lower surface 154 comprises theexterior surface in which openings 142 (shown here as partially formedin first cutaway section 104) are formed. As will be discussed furtherbelow, apertures 150 may extend from an initial hole along an exteriorsurface to form apertures of varying sizes and lengths through thickness140 of a cushioning element. Apertures 150 may be blind-hole aperturesin some embodiments, where only one end of each aperture is open orexposed, while the opposite end of each aperture remains enclosed withinthe thickness of the element (i.e., only one end of each aperture may beexposed on an exterior surface of the element).

Furthermore, in FIG. 2, it can be seen that in another embodiment, therecan be a second aperture set 202 comprising apertures 150 that extend ina direction generally aligned with vertical axis 170 through thickness140 of second element 200. In second cutaway section 204 of secondelement 200 of FIG. 2, apertures of second aperture set 202 are formedalong upper surface 152 and extend toward lower surface 154. Inaddition, in FIG. 2, openings 142 that comprise an exposed end ofapertures 150 can be seen disposed along upper surface 152.

It should also be understood that in some embodiments of cushioningelements, there may be apertures 150 that are formed along multiplesurfaces. For example, in FIG. 3, third aperture set 302 comprisingapertures 150 that extend in a direction generally aligned with verticalaxis 170 through thickness 140 of third element 300. However, in thisembodiment, as shown in third cutaway section 304, third aperture set302 includes apertures 150 with openings 142 formed along both lowersurface 154 and upper surface 152. Thus, third aperture set 302 includesupper set 324 and lower set 326. Apertures 150 comprising upper set 324extend from upper surface 152 toward lower surface 154, and apertures150 comprising lower set 326 extend from lower surface 154 toward uppersurface 152.

In different embodiments, the number of apertures 150 comprising eachset of apertures can vary. For example, in one embodiment, firstaperture set 102 can comprise between 1 and 100 apertures, or more than100 apertures. In another embodiment, first aperture set 102 cancomprise between 40 and 70 apertures. In still other embodiments, secondaperture set 202 can include more than 100 apertures. In addition, insome embodiments, second aperture set 202 can include between 1 and 30apertures. In other embodiments, second aperture set 202 can includemore than 30 apertures. Similarly, in some embodiments, third apertureset 302 can include a wide range of numbers of apertures 150. Thus,depending on the cushioning characteristics desired, there can be moreapertures or fewer apertures than illustrated in any set of aperturesformed in a portion of a cushioning element.

As noted above, in some embodiments, apertures 150 may extend variousdistances through a cushioning element. For example, as shown in FIG. 1,some apertures 150 of first aperture set 102 may not extend above lowerportion 184 of first element 100. However, other apertures 150 mayextend further upward, above lower portion 184 and into upper portion182. Likewise, in some cases, apertures 150 of second aperture set 202may only be disposed in upper portion 182, while other apertures 150 mayextend further downward. For example, an aperture may extend from uppersurface 152, and be disposed at least partially within lower portion184. It should be understood that the various portions can differ fromthat shown here and are for reference purposes only. Thus, apertures 150can include any length from zero to nearly the entire length, width, orheight of the cushioning element (including a diagonal length). In caseswhere the cushioning element varies in geometry from the generallyoblong rectangular shape shown in FIGS. 1-3, apertures can be formedsuch that they extend up to the maximum length, thickness, breadth, orwidth associated with the cushioning element. Thus, in some embodiments,the length of each aperture can vary with the size or dimensions of thecushioning element.

Generally, the shape of one or more apertures 150 in a cushioningelement can vary. In some cases, one or more apertures 150 may have alinear configuration or shape. In other cases, one or more apertures 150may have a non-linear configuration or shape. In the embodiments ofFIGS. 1-3, apertures 150 are shown having a generally linear shape, forexample.

In different embodiments, the dimensions of one or more apertures 150relative to one another can vary. For example, referring to FIG. 1, insome embodiments, the lengths of each aperture in first aperture set 102can vary. For example, in one embodiment, apertures 150 of firstaperture set 102 may be longer than other apertures 150 of firstaperture set 102. Thus, in FIG. 1, a first aperture 110 has a smallerlength than adjacent second aperture 112. In other cases, however, thelengths of each aperture in first aperture set 102 can vary in anothermanner. First aperture 110 may have a length that is substantiallysimilar to or greater than the length of second aperture 112, forexample. Thus, each aperture can have a length that differs from thelength of other apertures, and apertures 150 located in differentportions of a cushioning element can vary in length relative to oneanother. The length of an aperture can also vary with reference tolongitudinal axis 180 and/or lateral axis 190. Some examples of thisvariety will be described further below.

Additionally, the size of each aperture can vary. For purposes of thisdescription, the size of an aperture can refer to the cross-sectionaldiameter or size of an aperture. In some cases, the volume associatedwith the interior of an aperture can be correlated with the averagecross-sectional diameter of the aperture. Referring to FIG. 3, in somecases, each aperture in third aperture set 302 can have a substantiallysimilar size (e.g., cross-sectional diameter). In other cases, two ormore apertures in third aperture set 302 can have substantiallydifferent sizes. For example, a third aperture 310 has a size that issmaller than the size of adjoining fourth aperture 312. In other cases,however, the sizes of each aperture in third aperture set 302 can varyin another manner. Third aperture 310 may have a size that issubstantially similar to or greater than the size of fourth aperture312, for example. Thus, each aperture can have a size that differs fromthe size of other apertures, and apertures 150 located in differentportions of a cushioning element can vary in size relative to oneanother. In other cases, the size of each aperture can vary with thesize of the cushioning element. It should be understood that the size ofan aperture can vary throughout a single aperture, such that one regionof an aperture is larger or smaller than another region of the sameaperture. However, in other embodiments, the size of an aperture mayremain substantially constant throughout the length of the aperture.Some examples of this variety will be described further below.

In some embodiments, apertures on different portions of a cushioningelement can be generally parallel with one another with respect toanother surface or side of the element. In some cases, aperturesextending from the same surface of a cushioning element may be generallyparallel with one another, such that they do not intersect. In otherwords, the apertures may be generally oriented in a similar direction.For example, apertures formed on lower surface 154 or upper surface 152may be similarly oriented in a direction generally aligned with verticalaxis 170. Thus, in different embodiments, apertures 150 may beassociated with approximately similar longitudinal, lateral, or verticalorientations. In other embodiments, however, apertures on the sidesurfaces may not be parallel with one another. In one example, there maybe apertures with openings 142 on first side 156 that are oriented inone direction, and apertures with openings 142 on first side 156 thatare oriented along a different direction. Furthermore, it will beunderstood that in some embodiments, only some apertures may begenerally aligned through upper portion 182, lower portion 184, firstside portion 186, second side portion 188, forward portion 192, and/orrear portion 194, while other apertures disposed throughout thecushioning element may not be aligned. Therefore, it should beunderstood that while the embodiments of FIGS. 1-3 show apertures 150having lengths extending along vertical axis 170, apertures can also beoriented so that they lie along any other direction (e.g., a horizontal,diagonal, or non-planar direction). For example, in some embodiments,apertures can form an angle less than 90 and greater than 0 degrees withrespect to vertical axis 170, lateral axis 190, and/or longitudinal axis180. In some cases, apertures can form an angle between 30 and 60degrees with respect to vertical axis 170, lateral axis 190, and/orlongitudinal axis 180.

As a result of the inclusion of different possible configurations ofapertures 150, a cushioning element may have varying responsiveness toforces. In other words, apertures 150 can be disposed in a pattern thatcan help attenuate ground reaction forces and absorb energy, impartingdifferent cushioning characteristics to the element. In the embodimentsof FIGS. 4-9, a sequence of images representing possible responses ofthe cushioning elements under a load are shown.

For purposes of providing a contextual example to the reader, FIG. 4depicts an embodiment of a first sole member 400. In FIG. 5, a crosssection taken along the line 5-5 of FIG. 4 in first sole member 400 isshown, depicting fourth element 500. Fourth element 500 has a series ofapertures 150 disposed along lower surface 154 and extending throughthickness 140 at varying lengths. For example, apertures 150 disposednearer to third side 158 are longer than apertures 150 disposed nearerto center 550 of fourth element 500. Furthermore, apertures 150 disposednearer to center 550 of fourth element 500 are smaller than apertures150 disposed closer to first side 156. In some embodiments, apertures150 may form a geometric pattern. In other words, apertures 150 may bearranged such that there is a predictable rise and fall to the heightsof the apertures throughout the cushioning element. In FIGS. 5-6,apertures 150 decrease in length as they approach center 550 of fourthelement 500, and then increase in length as they move further away fromcenter 550. A regular arrangement as shown in fourth element 500 mayprovide more consistent cushioning for a user in some cases. However, itshould be understood that, in other embodiments, apertures 150 may havea random height arrangement.

For purposes of convenience, heights can be associated with differentportions of fourth element 500. In FIG. 5, a first height 510, a secondheight 520, and a third height 530 are identified. First height 510 isassociated with the portion of fourth element 500 toward first side 156,second height 520 is associated with the portion of fourth element 500toward center 550, and third height 530 is associated with the portionof fourth element 500 toward third side 158. In FIG. 5, first height510, second height 520, and third height 530 are substantially similar,such that thickness 140 is generally uniform through fourth element 500.

When fourth element 500 undergoes first load 600 (represented byarrows), as shown in FIG. 6, the arrangement of apertures 150 can alterthe cushioning responsiveness of the material. In FIG. 6, first load 600is directed downward in a direction generally aligned with vertical axis170 and distributed in a substantially constant or uniform manner overupper surface 152 of fourth element 500. As fourth element 500experiences the force of first load 600, fourth element 500 can deform.

In some embodiments, when cushioning elements are compressed, they candeform in different ways. The deformation that occurs can be related tothe location of any apertures, and/or the size and orientation of theapertures. Thus, apertures 150 may function together within the materialof the cushioning element to provide variations in the relativestiffness, degree of ground reaction force attenuation, and energyabsorption properties of the cushioning element. These cushioningcharacteristics may be altered to meet the specific demands of theactivity for which the cushioning element is intended to be used,through the methods described herein.

In some embodiments, when the compressive force of first load 600 isapplied to fourth element 500, for example, the areas that include moreapertures and/or apertures of greater size or length may deform to agreater extent than the portions of fourth element 500 that have fewerapertures and/or apertures of smaller size or length. As a result of theapplication of first load 600, the aperture openings can be compressedand/or deformed, as shown in FIG. 6. In the region nearest to third side158, where there are longer apertures relative to the center of fourthelement 500, the deformation is greater. Similarly, in the regionnearest to first side 156, where the apertures are longer relative tothe apertures disposed proximate center 550, the degree of deformationis greater. Thus, the least deformation of fourth element 500 occursnear center 550, where there are shorter or smaller apertures.

In some embodiments, the deformation that occurs throughout fourthelement 500 can be measurable in part by the changed shape and height offourth element 500 and/or the changed shape and heights of apertures150. Specifically, in FIG. 6, fourth height 610, fifth height 620, andsixth height 630 are identified. Fourth height 610 is associated withthe portion of fourth element 500 toward first side 156, fifth height620 is associated with the portion of fourth element 500 toward center550 of fourth element 500, and sixth height 630 is associated with theportion of fourth element 500 toward third side 158. Referring to FIGS.5 and 6, as a result of first load 600, it can be seen that fourthheight 610 is less than first height 510, fifth height 620 is less thansecond height 520, and sixth height 630 is less than third height 530.Furthermore, in FIG. 6, fourth height 610, fifth height 620, and sixthheight 630 are substantially different from one another, such thatthickness 140 is generally non-uniform through fourth element 500. Inother words, various contours have been formed along upper surface 152where first load 600 has been applied. The contours may vary in a mannergenerally corresponding to the arrangement of apertures 150 disposed infourth element 500 in some embodiments. Thus, fifth height 620 isgreater than both fourth height 610 and sixth height 630, and sixthheight 630 is greater than fourth height 610.

In some embodiments, the shape or orientation of the apertures may alsochange as a result of an applied force. Depending on the magnitude andthe direction of the force(s) applied, the changes in area or shape mayvary. For example, referring to FIG. 6, in one embodiment, fourthelement 500 may be exposed to a force or load whereby apertures becomedeformed not only by becoming more compact, but also by curling orotherwise becoming increasingly non-linear and/or irregular. In oneembodiment, the area or volume of an aperture may decrease when acompressive force is applied.

Similarly, compressive forces can produce responses in other types ofcushioning elements. For purposes of providing a contextual example tothe reader, FIG. 7 depicts an embodiment of second sole member 700. InFIG. 8, a cross-section taken along the line 8-8 of FIG. 7 in secondsole member 700 depicts an unloaded fifth cushioning element (“fifthelement”) 800. Fifth element 800 has a series of through-hole apertures150 extending from lower surface 154, through thickness 140, to uppersurface 152. As noted above, in some embodiments, apertures 150 may bedisposed along only some areas of fifth element 800. In FIGS. 8 and 9,fifth element 800 includes first region 860, second region 862, thirdregion 864, fourth region 866, fifth region 868, sixth region 870,seventh region 872, and eighth region 874. First region 860, thirdregion 864, fifth region 868, and seventh region 872 comprise portionsthat include apertures 150, while second region 862, fourth region 866,sixth region 870, and eighth region 874 comprise portions that do notinclude apertures 150.

When second sole member 700 and/or fifth element 800 undergo second load900 (represented by arrows), as shown in FIG. 9, the arrangement ofapertures 150 can alter the cushioning responsiveness of the material.In FIG. 9, second load 900 is directed downward in a direction generallyaligned with vertical axis 170 and distributed in a substantiallyconstant manner over upper surface 152 of fifth element 800. Similar tofourth element 500 described with respect to FIGS. 5-6, as fifth element800 experiences the force of second load 900, fifth element 800 candeform. The deformation that occurs can be related to the location ofany aperture, and/or the size and orientation of the apertures in someembodiments.

When the compressive force of second load 900 is applied to fifthelement 800, for example, the areas that include more apertures and/orapertures of greater size may deform to a greater extent than theportions of fifth element 800 that have fewer apertures and/or aperturesof smaller size. Thus, as a result of the application of second load900, any aperture openings or passageways can be compressed and/ordeformed. In some embodiments, in regions with apertures, the cushioningresponse can be greater relative to the regions without apertures.

For purposes of convenience, heights are associated with differentportions of fifth element 800. For example, referring to FIG. 8, seventhheight 810 is associated with third region 864, eighth height 820 isassociated with fourth region 866, and ninth height 830 is associatedwith seventh region 872. It can be seen that in the unloadedconfiguration of FIG. 8, seventh height 810, eighth height 820, andninth height 830 are substantially similar, such that thickness 140 isgenerally uniform through fifth element 800.

However, when fifth element 800 undergoes second load 900 (representedby arrows), as shown in FIG. 9, the arrangement of apertures 150 canalter the responsiveness of the material. In FIG. 9, tenth height 910associated with third region 864, eleventh height 920 associated withfourth region 866, and twelfth height 930 associated with seventh region872 can be identified.

Referring to FIGS. 8 and 9, in response to second load 900, the overallheight of fifth element 800 is lessened. For example, tenth height 910is less than seventh height 810, eleventh height 920 is less than eighthheight 820, and twelfth height 930 is less than ninth height 830.Comparing FIG. 8 with FIG. 9, it can be seen that in the regions wherethere are no apertures, the degree of deformation is substantially less.For example, while the entire surface of fifth element 800 is compressedand the overall height of the cushioning element decreases, variouscontours can be formed along upper surface 152 where second load 900 hasbeen applied. It can be seen that tenth height 910 differs substantiallyfrom eleventh height 920, and eleventh height 920 differs from twelfthheight 930, such that thickness 140 is generally non-uniform throughoutfifth element 800. In some embodiments, these contours may vary in amanner generally corresponding to the arrangement of apertures 150disposed in fifth element 800. Thus, eleventh height 920, which isassociated with an area that does not include apertures, is greater thantenth height 910 and twelfth height 930, which include apertures. Thisallows each area to provide different cushioning properties.

Thus, exposure to various forces may also produce a change in the shapeor geometry, size, and/or height of cushioning elements and theapertures that may be disposed within the cushioning element. It shouldbe understood that while first load 600 and second load 900 are shown asbeing generally uniform, other loads may be non-uniform. Depending onthe magnitude and the direction of the force(s) applied, changes inarea, volume, dimensions, and/or shape of the cushioning element mayvary. In some embodiments, a different force may permit the cushioningelement to expand in a lateral or longitudinal direction, such that theoverall length of the element increases. In other embodiments, differentforces may alter the responses of the cushioning element.

It should be noted that the various degrees of deformation described andshown here are for purposes of illustration. In some situations, thecushioning element may not undergo compression to the extent depicted,or may deform more or less, depending on various factors such as thematerials used in the production of the cushioning element, as well asits incorporation in other objects or articles. For example, if acushioning element is joined or attached to a less reactive material,the compressive and/or expansive properties described herein may differ,or be limited. In some embodiments, when the cushioning element isjoined to a strobel or other structure, the capacity of expansion maydecrease. In some embodiments, the perimeter of the cushioning elementmay be fixed, e.g., bonded to a strobel layer or another sole layer.However, in such embodiments, the cushioning characteristics of thecushioning element may still facilitate increased flexibility andcushioning.

Furthermore, it should be understood that while fourth element 500 andfifth element 800 may experience various forces and deformation, thedeformation may be elastic. In other words, once the load is removed ordecreased, the cushioning element may recover and return to its originaldimensions and/or shape, or to dimensions and/or a shape substantiallysimilar to the original, unloaded configuration.

It should be understood that, in some embodiments, the shape ororientation of the apertures may also change. Depending on the magnitudeand the direction of the force(s) applied, the changes in area or shapemay vary. For example, in one embodiment, fourth element 500 and/orfifth element 800 may be exposed to a force or load whereby aperturesbecome deformed not only by becoming more compact, but also by curlingor otherwise becoming increasingly non-linear and/or irregular. In oneembodiment, the area or volume of an aperture may increase when acompressive force is applied.

Referring to FIGS. 10-19, in different embodiments, a specific patternmay be selected and/or formed in the cushioning elements. In someembodiments, the cushioning characteristics of a cushioning element maybe modified by removing material and/or drilling apertures in thecushioning element to form a specific pattern. In some embodiments, aplurality of apertures may be disposed in a regular or irregular patternalong a portion of a cushioning element. In some cases, the aperturescan be disposed in regular intervals. For purposes of this disclosure, aregular pattern refers to a consistent (or otherwise generallyunvarying), repeating, geometric, periodic, steady, and/or reoccurringarrangement. For example, a plurality of openings or apertures that aredisposed in a circular, ring, or other geometric shape may be regularlyarranged.

In some embodiments, apertures can be disposed along a commoncircumference, or extend along a common radius, to form a regularpattern. Apertures located along or associated with the samecircumference can be understood to mean that the apertures are disposedat a substantially similar radial distance from a center point. Forpurposes of this disclosure, apertures disposed on a common or the samecircumference may also be understood to describe apertures that aredisposed in a manner that form a generally round or curved perimeter orboundary. The “circumference” can be continuous or discontinuous indifferent embodiments. In other words, the boundary of a circumferencecan be continuous (i.e., a solid or unbroken boundary or shape), ordiscontinuous (i.e., a general boundary or shape that is broken, suchthat the shape is implied by the arrangement of the apertures, and canbe dotted, or include spaces or openings along the perimeter of theshape).

A few examples of regular patterns that may be formed in a cushioningelement are depicted in FIGS. 10-13. It should be understood that thesepatterns are for illustrative purposes only, and any other aperturepattern may be formed using the principles disclosed herein. In FIG. 10,a regular first pattern (“first pattern”) 1000 is shown. First pattern1000 has a generally round configuration, comprising a series ofapertures 150 disposed in a repeated circular arrangement. In otherwords, there are multiple circumferences (of apertures) of differentsizes in first pattern 1000. In other embodiments, a first pattern mayrefer to a single circumference within a larger aperture pattern.

As noted above, it should be understood that the pattern depicted infirst pattern 1000 may include apertures 150 of various shapes and/ordimensions. Thus, apertures 150 may be round or another regular orirregular shape. Furthermore, apertures 150 may comprise differentlengths. For example, 16 apertures are depicted in cross-sectional view1050 of first pattern 1000 taken across the line 10-10. Incross-sectional view 1050, a first aperture 1052, a second aperture1054, a third aperture 1056, a fourth aperture 1058, a fifth aperture1060, a sixth aperture 1062, a seventh aperture 1064, an eighth aperture1066, a ninth aperture 1068, a tenth aperture 1070, an eleventh aperture1072, a twelfth aperture 1074, a thirteenth aperture 1076, a fourteenthaperture 1078, a fifteenth aperture 1080, and a sixteenth aperture 1082are shown. It should be understood that in other embodiments there maybe a greater or lesser number of apertures included in first pattern1000 than shown here.

In some embodiments, each aperture may have a length that differs fromthat of an adjacent aperture, or one or more apertures may have asubstantially similar length. In some cases, apertures 150 may have anoscillating or tapering pattern of lengths. For example, incross-sectional view 1050 of FIG. 10 it can be seen that apertures 150decrease in length as they approach a center 1010 (i.e., in a radiallyinward direction), and then increase in length again as they move awayfrom center 1010 (i.e., move in a radially outward direction). Forpurposes of this disclosure, center 1010 may refer to the approximateorigin of the circumference of apertures depicted. As an illustration,in some cases, first aperture 1052 can have a first length 1012, thirdaperture 1056 can have a second length 1014, eighth aperture 1066 canhave a third length 1016, and sixteenth aperture 1082 can have a fourthlength 1018. In some embodiments, first length 1012 may be greater thansecond length 1014. In some embodiments, second length 1014 may begreater than third length 1016. Furthermore, third length 1016 and/orsecond length 1014 may be smaller than fourth length 1018. In somecases, different apertures can have similar lengths. In one embodiment,first length 1012 may be substantially similar to fourth length 1018.

In different embodiments, a “mirrored” pattern may be formed. In oneembodiment, apertures disposed along the same circumference can havesubstantially similar lengths. In other words, apertures disposed alongthe same circumference may be substantially similar in length to oneanother. Thus, in one case, fifth aperture 1060 and twelfth aperture1074, being disposed on the same circumference, may comprise similarlengths. In some embodiments, two or more apertures disposed along acommon circumference may have similar lengths. However, in otherembodiments, the lengths of apertures may differ from that shown here,may have a different repeated pattern, or may be random.

In addition, referring to FIG. 10, it can be seen that each aperture maybe disposed at a distance from its neighboring aperture. In differentembodiments, the distances between apertures may be similar or they mayvary. In one embodiment, the distance between two apertures may varybased on whether the two apertures are disposed along a commoncircumference (i.e., are disposed at a similar radial distance fromcenter 1010), or whether they are disposed along differentcircumferences.

As shown in FIG. 10, in some cases, there may be two or more aperturesdisposed adjacent to one another, but disposed on differentcircumferences. In cross-sectional view 1050, it can be seen that firstaperture 1052 is spaced at a first radial distance 1028 from secondaperture 1054, and seventh aperture 1064 is spaced at a second radialdistance 1030 from eighth aperture 1066. In addition, eighth aperture1066 is spaced at a third radial distance 1032 from ninth aperture 1068,and eleventh aperture 1072 is spaced at a fourth radial distance 1034from twelfth aperture 1074. In some embodiments, first radial distance1028 can be similar to or different from second radial distance 1030. InFIG. 10, first radial distance 1028 is substantially similar to bothsecond radial distance 1030 and fourth radial distance 1034. In otherwords, apertures adjacent to one another and disposed along neighboringcircumferences may be spaced apart from one another at generally uniformdistances.

However, in some embodiments, there may be a greater or lesser distancebetween apertures disposed on different circumferences. In some cases,some apertures can be spaced apart at irregular distances from oneanother. In one example, third radial distance 1032 can be greater thanfirst radial distance 1028, second radial distance 1030, and/or fourthradial distance 1034. In one embodiment, third radial distance 1032 mayrepresent the diameter of the circumference in which eighth aperture1066 and ninth aperture 1068 are arranged. In some embodiments, thirdradial distance 1032 may be approximately twice as large as first radialdistance 1028. In other embodiments, third radial distance 1032 may bemore than twice as great as first radial distance 1028. In other words,a portion of a cushioning element disposed proximate to center 1010 maynot include apertures. In one embodiment, the distance between eighthaperture 1066 and ninth aperture 1068 may be a reflection of the lack ofadditional circumferentially disposed apertures near center 1010.

Similarly, in different embodiments, apertures that are disposedadjacent to one another and that share a common circumference can bespaced apart at regular or similar intervals. For example, in FIG. 10, aseventeenth aperture 1084 and an eighteenth aperture 1086 are separatedby a first circumferential distance 1020, and a nineteenth aperture 1088and a twentieth aperture 1090 are separated by a second circumferentialdistance 1022. In some embodiments, first circumferential distance 1020and second circumferential distance 1022 may be substantially similar orthey may differ. In FIG. 10, first circumferential distance 1020 andsecond circumferential distance 1022 are substantially similar. Thus, insome embodiments, apertures disposed along a common circumference may bespaced uniformly apart from one another.

Furthermore, the distance between neighboring apertures disposed along afirst circumference can differ or be similar to the distance betweenneighboring apertures disposed along a second circumference. Forexample, a twenty-first aperture 1092 and a twenty-second aperture 1094disposed on a common first circumference can be separated by a thirdcircumferential distance 1024, and a twenty-third aperture 1096 and atwenty-fourth aperture 1098 disposed on a common second circumferenceare separated by a fourth circumferential distance 1026. In someembodiments, third circumferential distance 1024 and fourthcircumferential distance 1026 can be similar. In other embodiments,third circumferential distance 1024 and fourth circumferential distance1026 can differ. In FIG. 10, third circumferential distance 1024 isgreater than fourth circumferential distance 1026.

It may also be understood that, in some cases, a circumferentialdistance may be close to zero or be approximately zero such that twoapertures are touching or merged. For example, a twenty-fifth aperture1097 and twenty-sixth aperture 1099 on the circumference nearest center1010 are shown to be nearly touching one another. In other embodiments,two apertures may be disposed close enough to one another so as to forma substantially continuous opening similar to a siping. This featurewill be discussed further with respect to FIGS. 11 and 12.

In some cases, a pattern can be formed whereby the distances betweenapertures disposed along a common circumference may decrease or increasealong a direction. For example, in first pattern 1000, apertures thatare disposed further radially outward from center 1010 are spaced apartat larger distances, while apertures that are disposed further radiallyinward toward center 1010 are spaced from one another at relativelycloser distances. For example, in the direction extending from anoutermost perimeter 1040 to center 1010, the distance between aperturescan decrease or increase. Thus, in one embodiment, first circumferentialdistance 1020 may be greater than third circumferential distance 1024,and third circumferential distance 1024 may be greater than fourthcircumferential distance 1026.

In FIG. 11, a regular second pattern (“second pattern”) 1100 is shown.Similar to first pattern 1000 of FIG. 10, second pattern 1100 has agenerally round configuration, comprising a series of apertures 150disposed in a repeated circular arrangement. As noted above, it shouldbe understood that the pattern depicted in second pattern 1100 mayinclude apertures 150 of various shapes and/or dimensions. Thus,apertures 150 may be round or another regular or irregular shape.

Furthermore, apertures 150 may comprise different or similar lengths.For example, 16 apertures are depicted in a cross-sectional view 1150 ofsecond pattern 1100, taken across the line 11-11. In cross-sectionalview 1150, a first aperture 1152, a second aperture 1154, a thirdaperture 1156, a fourth aperture 1158, a fifth aperture 1160, a sixthaperture 1162, a seventh aperture 1164, an eighth aperture 1166, a ninthaperture 1168, a tenth aperture 1170, an eleventh aperture 1172, atwelfth aperture 1174, a thirteenth aperture 1176, a fourteenth aperture1178, a fifteenth aperture 1180, and a sixteenth aperture 1182 areshown. It should be understood that in other embodiments there may be agreater or lesser number of apertures included in second pattern 1100than shown here.

In some embodiments, each aperture may have a length that differs fromthat of an adjacent aperture, or one or more apertures may have asubstantially similar length. In some cases, apertures 150 may have anoscillating or tapering pattern of lengths. For example, incross-sectional view 1150 of FIG. 11, it can be seen that apertures 150increase in length as they approach a center 1110 (i.e., in a radiallyinward direction), and then decrease in length again as they move awayfrom center 1110 (i.e., radially outward). For purposes of thisdisclosure, center 1110 may refer to the approximate origin of thecircumference of apertures depicted. As an illustration, in some cases,first aperture 1152 can have a first length 1112, third aperture 1156can have a second length 1114, eighth aperture 1166 can have a thirdlength 1116, and sixteenth aperture 1182 can have a fourth length 1118.In some embodiments, first length 1112 may be smaller than second length1114. In some embodiments, second length 1114 may be smaller than thirdlength 1116. Furthermore, third length 1116 and/or second length 1114may be greater than fourth length 1118. In some cases, differentapertures can have similar lengths. In one embodiment, first length 1112may be substantially similar to fourth length 1118.

In different embodiments, similar to FIG. 10, a “mirrored” pattern maybe formed. In one embodiment, apertures disposed along the samecircumference can have substantially similar lengths. In other words,apertures disposed along the same circumference may be substantiallysimilar in length to one another. Thus, in one case, fifth aperture 1160and twelfth aperture 1174 may have similar lengths. In some embodiments,two or more apertures disposed along a common circumference may havesimilar lengths. However, in other embodiments, the lengths of aperturesmay differ from that shown here, may have a different repeated pattern,or may be random.

In addition, referring to FIG. 11, it can be seen that each aperture canbe disposed at a distance from its neighboring aperture. In someembodiments, the distances between apertures 150 may be similar or theymay vary. The distances between two apertures may be varied based onwhether the two apertures are disposed along a common circumference(i.e., are disposed at a similar radial distance from center 1110), orwhether they are disposed along different circumferences.

As shown in FIG. 11, in some cases, there may be two or more aperturesdisposed adjacent to one another, yet disposed on differentcircumferences. In cross-sectional view 1150, it can be seen that firstaperture 1152 is spaced at a first radial distance 1128 from secondaperture 1154, while seventh aperture 1164 is spaced at a second radialdistance 1130 from eighth aperture 1166. In addition, eighth aperture1166 is spaced at a third radial distance 1132 from ninth aperture 1168,and tenth aperture 1170 is spaced at a fourth radial distance 1134 fromeleventh aperture 1172. In some embodiments, first radial distance 1128can be similar to or differ from second radial distance 1130. In FIG.11, first radial distance 1128 is substantially similar to both secondradial distance 1130 and fourth radial distance 1134. In other words,apertures arranged along neighboring circumferences may be spaced apartat generally uniform distances.

However, in some embodiments, there may be a greater or lesser distancebetween apertures disposed on different circumferences. In some cases,such apertures can be spaced apart at irregular distances from oneanother. In one example, third radial distance 1132 can be greater thanfirst radial distance 1128, second radial distance 1130, and/or fourthradial distance 1134. In one embodiment, third radial distance 1132 mayrepresent the diameter of the circumference in which eighth aperture1166 and ninth aperture 1168 are arranged. In one embodiment, thirdradial distance 1132 may be approximately twice as large as first radialdistance 1128. In other embodiments, third radial distance 1132 may bemore than twice as great as first radial distance 1128. In other words,a portion of a cushioning element disposed proximate to center 1110 maynot include apertures. In one embodiment, the distance between eighthaperture 1166 and ninth aperture 1168 may be larger, reflecting a lackof additional apertures disposed toward center 1110.

Furthermore, in different embodiments, apertures disposed adjacent toone another and that share a common circumference can be spaced apart atregular or similar intervals. For example, in FIG. 11, a seventeenthaperture 1184 and an eighteenth aperture 1186 are separated by a firstcircumferential distance 1120, and a nineteenth aperture 1188 and atwentieth aperture 1190 are separated by a second circumferentialdistance 1122. In some embodiments, first circumferential distance 1120and second circumferential distance 1122 may be substantially similar orthey may differ. In FIG. 11, first circumferential distance 1120 andsecond circumferential distance 1122 are substantially similar. Thus, insome embodiments, apertures disposed along a common circumference may bespaced uniformly apart from one another.

In addition, the distance between neighboring apertures disposed along afirst circumference can differ or be similar to the distance betweenneighboring apertures disposed along a second circumference. Forexample, a twenty-first aperture 1192 and a twenty-second aperture 1194disposed on a common first circumference can be separated by a thirdcircumferential distance 1124, and a twenty-third aperture 1196 and atwenty-fourth aperture 1198 disposed on a common second circumferenceare separated by a fourth circumferential distance 1126. In someembodiments, third circumferential distance 1124 and fourthcircumferential distance 1126 can be similar. In other embodiments,third circumferential distance 1124 and fourth circumferential distance1126 can differ. In FIG. 11, third circumferential distance 1124 isgreater than fourth circumferential distance 1126.

As noted above, in some embodiments, a circumferential distance betweentwo apertures may be close to zero or be approximately zero. In otherwords, two apertures can approach, touch, and/or merge with one another.For example, an innermost circumference comprising a first circumference1181 includes a series of apertures whose edges are touching oneanother. In other words, each aperture of first circumference 1181 isdisposed close enough to one another so as to form a substantiallycontinuous opening similar to a siping. In different embodiments, thissiping facsimile can be a result of the varying degrees of mergingbetween adjoining apertures. In some embodiments, apertures may beformed in various portions of a cushioning element to create asiping-like region, groove, or channel, through the cushioning element.While the arrangement can provide variations in cushioning, there may beother benefits, including enhanced traction or grip of the exteriorsurface. Various designs or flexible regions may also be formed by theinclusion of such siped apertures.

Furthermore, in some embodiments, a pattern can be formed whereby thedistances between apertures disposed along a common circumference maydecrease or increase along a direction. For example, in second pattern1100, apertures that are disposed further radially outward are spacedapart at larger distances, while apertures that are disposed furtherradially inward are spaced apart at closer distances. For example, inthe direction extending from an outermost perimeter 1140 to center 1110,the distance between apertures can decrease or increase. Thus, in oneembodiment, first circumferential distance 1120 may be greater thanthird circumferential distance 1124, and third circumferential distance1124 may be greater than fourth circumferential distance 1126.

In FIG. 12, a regular third pattern (“third pattern”) 1200 is shown.Similar to first pattern 1000 of FIG. 10 and second pattern 1100 of FIG.11, third pattern 1200 has a generally round configuration, comprising aseries of apertures 150 disposed in a repeated circular arrangement. Asnoted above, it should be understood that the pattern depicted in thirdpattern 1200 may include apertures 150 of various shapes and/ordimensions. Thus, apertures 150 may be round or another regular orirregular shape.

Furthermore, apertures 150 may comprise different lengths or havesubstantially similar lengths. For example, 24 apertures are depicted ina cross-sectional view 1250 of third pattern 1200 taken across the line12-12. In cross-sectional view 1250, a first aperture 1252, a secondaperture 1254, a third aperture 1256, a fourth aperture 1258, a fifthaperture 1260, a sixth aperture 1262, a seventh aperture 1264, an eighthaperture 1266, a ninth aperture 1268, a tenth aperture 1270, an eleventhaperture 1272, a twelfth aperture 1274, a thirteenth aperture 1276, afourteenth aperture 1278, a fifteenth aperture 1280, a sixteenthaperture 1282, a seventeenth aperture 1284, an eighteenth aperture 1286,a nineteenth aperture 1288, a twentieth aperture 1290, a twenty-firstaperture 1292, a twenty-second aperture 1294, a twenty-third aperture1296, and a twenty-fourth aperture 1298 are shown. It should beunderstood that in other embodiments there may be a greater or lessernumber of apertures disposed in third pattern 1200 than shown here.

In some embodiments, each aperture may have a length that differs fromthat of an adjacent aperture, or one or more apertures may have asubstantially similar length. In some cases, apertures 150 may have agenerally consistent length throughout third pattern 1200. For example,in cross-sectional view 1250 of FIG. 12, it can be seen that apertures150 remain generally uniform in length as they approach a center 1210(i.e., move in a radially inward direction), and also as they moveradially outward (away from center 1210). For purposes of thisdisclosure, center 1210 may refer to the approximate origin of thecircumference of apertures depicted. As an illustration, in some cases,first aperture 1252 can have a first length 1212 and twelfth aperture1274 can have a second length 1214. In one embodiment, first length 1212may be substantially similar to second length 1214. In other cases, allapertures in a pattern may have substantially similar lengths. In otherwords, apertures disposed along the same circumference and on differentcircumferences may be substantially similar in length to one another.However, in other embodiments, the lengths of apertures may differ fromthat shown here, may have a different repeated length pattern, or mayhave a random length arrangement.

In FIG. 12, it can be seen that the apertures can be spaced fromneighboring apertures at varying distances. The distances betweenapertures may be varied based on whether the two apertures are disposedalong a common circumference (i.e., are disposed at a similar radialdistance from center 1210), or whether they are disposed along differentcircumferences.

As shown in FIG. 12, in some cases, there may be two or more aperturesdisposed adjacent to one another, but disposed on differentcircumferences. In cross-sectional view 1250, it can be seen that firstaperture 1252 is spaced at a first radial distance 1228 from secondaperture 1254, and fourth aperture 1258 is spaced at a second radialdistance 1230 from fifth aperture 1260. In addition, tenth aperture 1270is spaced at a third radial distance 1232 from eleventh aperture 1272,and twelfth aperture 1274 is spaced at a fourth radial distance 1234from thirteenth aperture 1276. In some embodiments, first radialdistance 1228 can be similar to or different from second radial distance1230. In FIG. 12, first radial distance 1228 is substantially largerthan either second radial distance 1230 or third radial distance 1232.Furthermore, second radial distance 1230 is greater than third radialdistance 1232. In other words, apertures arranged along neighboringcircumferences may be spaced apart at different distances.

In different embodiments, there may be a geometric pattern to thespacing between apertures. In some embodiments, the distances betweenapertures can decrease as they approach center 1210 (i.e., in a radiallyinward direction), and then increase again as they move radially outward(move away from center 1210). It should be understood that in othercases, the distances between apertures can increase as they approachcenter 1210 (i.e., in a radially inward direction), and then decreaseagain as they move radially outward. In one embodiment, the spacingbetween apertures can be mirrored. For example, the distance between twoapertures can be substantially similar to the distance between twoapertures disposed the opposite side (i.e., between apertures disposedalong the same two neighboring circumferences). In other words,apertures disposed along the same two circumferences may be spaced atsubstantially similar distances from one another.

In some embodiments, there may be larger portions of a cushioningelement that does not include apertures. For example, fourth radialdistance 1234 can be greater than first radial distance 1228, secondradial distance 1230, and/or third radial distance 1232. In oneembodiment, fourth radial distance 1234 may represent the diameter ofthe circumference in which twelfth aperture 1274 and thirteenth aperture1276 are arranged. In one embodiment, fourth radial distance 1234 may beapproximately twice as large as third radial distance 1232. In otherembodiments, fourth radial distance 1234 may be more than twice as greatas third radial distance 1232. In other words, center 1210 may beassociated with a portion of a cushioning element that does not includeapertures. In one embodiment, the distance extending between twelfthaperture 1274 and thirteenth aperture 1276 may be larger due to theabsence of any additional apertures. In other embodiments, fourth radialdistance 1234 can be less than or similar to first radial distance 1228,second radial distance 1230, and/or third radial distance 1232.

Furthermore, in different embodiments, apertures disposed adjacent toone another and that share a common circumference can be spaced apart atregular or similar intervals. For example, in FIG. 12, a twenty-fifthaperture 1202 and a twenty-sixth aperture 1204 are separated by a firstcircumferential distance 1220, and a twenty-seventh aperture 1206 and atwenty-eighth aperture 1208 are separated by a second circumferentialdistance 1222. In some embodiments, first circumferential distance 1220and second circumferential distance 1222 may be substantially similar,or they may differ. In FIG. 12, first circumferential distance 1220 andsecond circumferential distance 1222 are substantially similar. Thus, insome embodiments, apertures disposed along a common circumference may bespaced uniformly apart from one another.

Furthermore, the distance between neighboring apertures disposed along afirst circumference can differ or be similar to the distance betweenneighboring apertures disposed along a second, different circumference.For example, a twenty-ninth aperture 1236 and a thirtieth aperture 1238disposed on a common first circumference can be separated by a thirdcircumferential distance 1224, and a thirty-first aperture 1244 and athirty-second aperture 1246 disposed on a common second circumferenceare separated by a fourth circumferential distance 1226. In someembodiments, third circumferential distance 1224 and fourthcircumferential distance 1226 can be similar. In other embodiments,third circumferential distance 1224 and fourth circumferential distance1226 can differ. In FIG. 12, third circumferential distance 1224 isgreater than fourth circumferential distance 1226.

As described with respect to FIG. 11, in some embodiments, acircumferential distance between two apertures may be close to zero orbe approximately zero. In other words, two apertures can approach,touch, and/or merge with one another. For example, an innermostcircumference 1297 includes a series of apertures whose edges aretouching one another. In other words, each aperture of innermostcircumference 1297 is disposed close enough to one another so as to forma substantially continuous opening similar to a siping. In someembodiments, apertures may be formed in various portions of a cushioningelement to create a siping-like region, groove, or channel, through thecushioning element. While the arrangement can provide variations incushioning, there may be other benefits, including enhanced traction orgrip of the exterior surface. Various designs or flexible regions mayalso be formed by the inclusion of such siped apertures.

Thus, similar to first pattern 1000 in FIG. 10 and second pattern 1100in FIG. 11, in some cases, a pattern can be formed whereby the distancesbetween apertures disposed along a common circumference may decrease orincrease along a direction. In one embodiment, in the directionextending from an outermost perimeter 1240 to center 1210, distancebetween apertures can decrease or increase. For example, in thirdpattern 1200, apertures that are disposed further radially outward arespaced apart at larger distances, while apertures that are disposedfurther radially inward are spaced apart at closer distances. Thus, inone embodiment, first circumferential distance 1220 may be greater thanthird circumferential distance 1224, and third circumferential distance1224 may be greater than fourth circumferential distance 1226.

In FIG. 13, a regular fourth pattern (“fourth pattern”) 1300 is shown.Similar to first pattern 1000 of FIG. 10, second pattern 1100 of FIG.11, and third pattern 1200 of FIG. 12, fourth pattern 1300 has agenerally round configuration, comprising a series of apertures 150disposed in a repeated circular arrangement. As noted above, it shouldbe understood that the pattern depicted in fourth pattern 1300 mayinclude apertures 150 of various shapes and/or dimensions. Thus,apertures 150 may be round or another regular or irregular shape.

Furthermore, apertures 150 may comprise different lengths or havesubstantially similar lengths. For example, 24 apertures are depicted ina cross-sectional view 1350 of fourth pattern 1300 taken across the line13-13. In cross-sectional view 1350, a first aperture 1352, a secondaperture 1354, a third aperture 1356, a fourth aperture 1358, a fifthaperture 1360, a sixth aperture 1362, a seventh aperture 1364, an eighthaperture 1366, a ninth aperture 1368, a tenth aperture 1370, an eleventhaperture 1372, a twelfth aperture 1374, a thirteenth aperture 1376, afourteenth aperture 1378, a fifteenth aperture 1380, a sixteenthaperture 1382, a seventeenth aperture 1384, an eighteenth aperture 1386,a nineteenth aperture 1388, a twentieth aperture 1390, a twenty-firstaperture 1392, a twenty-second aperture 1394, a twenty-third aperture1396, and a twenty-fourth aperture 1398 are shown. It should beunderstood that in other embodiments there may be a greater or lessernumber of apertures disposed in fourth pattern 1300 than shown here.

In some embodiments, each aperture may have a length that differs fromthat of an adjacent aperture, or one or more apertures may have asubstantially similar length. In some cases, apertures 150 may have agenerally consistent length throughout fourth pattern 1300. For example,in cross-sectional view 1350 of FIG. 13, it can be seen that apertures150 comprise an undulating pattern of lengths as they approach a center1310 (i.e., in a radially inward direction), and also as they moveradially outward. For purposes of this disclosure, center 1310 may referto the approximate origin of the circumference of apertures depicted. Asan illustration, in some cases, first aperture 1352 can have a firstlength 1312 and fourth aperture 1358 can have a second length 1314. Insome cases, different apertures can have different lengths. In FIG. 13,first length 1312 is substantially greater than second length 1314. Inaddition, a third length 1316 is associated with twelfth aperture 1374.Third length 1316 may be substantially similar to second length 1314 insome embodiments. Furthermore, a fourth length 1318 may be substantiallysimilar to first length 1312. In other words, there may be apertureswith similar lengths throughout fourth pattern 1300. In FIG. 13,apertures are configured such that the lengths of alternating apertures(in a direction extending from an outermost perimeter 1340 toward center1310) have similar lengths.

In other cases, all apertures in a pattern may have substantiallysimilar lengths. In other words, apertures disposed along the samecircumference and on different circumferences may be substantiallysimilar in length to one another. However, in other embodiments, thelengths of apertures may differ from that shown here, may have adifferent repeated pattern, or may be random.

In FIG. 13, it can be seen that each aperture may be spaced at adistance from a neighboring aperture. In some embodiments, the distancesbetween apertures 150 may vary. The distances between apertures may bevaried based on whether the two apertures are disposed along a commoncircumference (i.e., are disposed at a similar radial distance fromcenter 1310), or whether they are disposed along differentcircumferences.

As shown in FIG. 13, in some cases, there may be two or more aperturesdisposed adjacent to one another, but disposed on differentcircumferences. In cross-sectional view 1350, it can be seen that firstaperture 1352 is spaced at a first radial distance 1328 from secondaperture 1354, and third aperture 1356 is spaced at a second radialdistance 1330 from fourth aperture 1358. In addition, eighth aperture1366 is spaced from ninth aperture 1368 by a third radial distance 1332,and tenth aperture 1370 is spaced by a fourth radial distance 1334 fromeleventh aperture 1372. Furthermore, twelfth aperture 1374 is spaced ata fifth radial distance 1336 from thirteenth aperture 1376. In someembodiments, the various radial distances can be similar to or differentfrom one another. In FIG. 13, first radial distance 1328 issubstantially larger than either second radial distance 1330, thirdradial distance 1332, or fourth radial distance 1334. Furthermore,second radial distance 1330 is greater than third radial distance 1332and fourth radial distance 1334. In other words, apertures arrangedalong neighboring circumferences may be disposed at different distancesfrom one another.

In different embodiments, there may be a geometric pattern to thespacing between apertures. In some embodiments, the distances betweenapertures can decrease as they approach center 1310 (i.e., in a radiallyinward direction), and then increase again as they move radially outward(move away from center 1310). It should be understood that in otherembodiments, the distances between apertures can increase as theyapproach center 1310 (i.e., in a radially inward direction), and thendecrease again as they move radially outward. In one embodiment, thespacing between apertures can be mirrored. For example, the distancebetween two apertures can be substantially similar to the distancebetween two apertures disposed the opposite side (i.e., betweenapertures disposed along the same two neighboring circumferences). Inother words, apertures disposed along the same two circumferences may bespaced at substantially similar distances from one another.

In some embodiments, there may be larger portions of a cushioningelement that does not include apertures. For example, fifth radialdistance 1336 can be greater than first radial distance 1328, secondradial distance 1330, third radial distance 1332, and/or fourth radialdistance 1334. In one embodiment, fifth radial distance 1336 mayrepresent the diameter of the circumference in which twelfth aperture1374 and thirteenth aperture 1376 are arranged. In other embodiments,fifth radial distance 1336 can be less than first radial distance 1328,second radial distance 1330, third radial distance 1332, and/or fourthradial distance 1334. In one embodiment, fifth radial distance 1336 maybe approximately twice as large as third radial distance 1332. In otherembodiments, fifth radial distance 1336 may be more than twice as greatas third radial distance 1332.

Thus, in some embodiments, there may be larger portions of a cushioningelement that does not include apertures. For example, in one embodiment,the distance extending across from twelfth aperture 1374 to thirteenthaperture 1376 may be larger due to the absence of any additionalapertures.

In different embodiments, apertures disposed adjacent to one anotherthat share a common circumference can be spaced apart at regular orsimilar intervals. For example, in FIG. 13, a twenty-fifth aperture 1302and a twenty-sixth aperture 1304 are separated by a firstcircumferential distance 1320, and a twenty-seventh aperture 1306 and atwenty-eighth aperture 1308 are separated by a second circumferentialdistance 1322. In some embodiments, first circumferential distance 1320and second circumferential distance 1322 may be substantially similar orthey may differ. In FIG. 13, first circumferential distance 1320 andsecond circumferential distance 1322 are substantially similar. Thus, insome embodiments, apertures disposed along a common circumference may bespaced uniformly apart from one another.

Furthermore, the distance between neighboring apertures disposed along afirst circumference can differ or be similar to the distance betweenneighboring apertures disposed along a second circumference. Forexample, a twenty-ninth aperture 1337 and a thirtieth aperture 1338disposed on a common first circumference can be separated by a thirdcircumferential distance 1324, and a thirty-first aperture 1344 and athirty-second aperture 1346 disposed on a common second circumferenceare separated by a fourth circumferential distance 1326. In someembodiments, third circumferential distance 1324 and fourthcircumferential distance 1326 can be similar. In other embodiments,third circumferential distance 1324 and fourth circumferential distance1326 can differ. In FIG. 13, third circumferential distance 1324 isgreater than fourth circumferential distance 1326.

Thus, similar to the regular patterns described above in FIGS. 10-12, insome cases, a pattern can be formed whereby the distances betweenapertures disposed along a common circumference may decrease or increasealong a direction. In one embodiment, in the direction extending fromoutermost perimeter 1340 to center 1310, the distance between aperturescan decrease or increase. For example, in fourth pattern 1300, aperturesthat are disposed further radially outward are spaced apart at largerdistances, while apertures that are disposed further radially inward arespaced apart at closer distances. In one embodiment, firstcircumferential distance 1320 may be greater than third circumferentialdistance 1324, and third circumferential distance 1324 may be greaterthan fourth circumferential distance 1326.

In different embodiments, it should be understood that eachcircumference described herein may include apertures disposed at asubstantially similar radial distance from a center point. In otherwords, each circumferential pattern may have a plurality of apertures,and each of the plurality of apertures may be located at a substantiallysimilar distance from the center of the circumferential pattern.Furthermore, referring to FIGS. 10-13. It can be seen that when two ormore circumferential patterns are disposed adjacent to one another, in amanner where a first circumference evenly bounds a second circumference(i.e., each circumference shares a substantially similar center point),they may be distinguished by their respective differences in radialdistance from the center.

For example, in FIG. 10, a first circumference 1081 comprising a firstset of apertures is disposed in first pattern 1000. Generally boundingfirst circumference 1081 is a second circumference 1083 comprising asecond set of apertures. Referring to cross-sectional view 1050, it maybe understood that eighth aperture 1066 and ninth aperture 1068 arelocated along first circumference 1081. Furthermore, seventh aperture1064 and tenth aperture 1070 are located along second circumference1083. In some embodiments, each of the apertures comprising firstcircumference 1081 (including eighth aperture 1066 and ninth aperture1068) may be disposed at a first radial distance 1087 from center 1010.In addition, in some embodiments, each of the apertures comprisingsecond circumference 1083 (seventh aperture 1064 and tenth aperture1070) may be disposed at a second radial distance 1085 from center 1010.Because center 1010 is being used as the reference point, in this case,first radial distance 1087 and second radial distance 1085 may beunderstood to refer to the approximate radius of each circumference. Asshown in FIG. 10, in some embodiments, first radial distance 1087 may beless than second radial distance 1085. In other words, each of theapertures comprising first circumference 1081 may be disposed closer tocenter 1010 than each of the apertures comprising second circumference1083. Furthermore, in one embodiment, each of the apertures comprisingfirst circumference 1081 may be disposed at substantially the sameradial distance from center 1010. In another embodiment, each of theapertures comprising second circumference 1083 may be disposed atsubstantially the same radial distance from center 1010.

Similarly, in FIG. 11, first circumference 1181 comprising a first setof apertures is disposed in second pattern 1100. Generally boundingfirst circumference 1181 is a second circumference 1183 comprising asecond set of apertures. Referring to cross-sectional view 1150, it maybe understood that eighth aperture 1166 and ninth aperture 1168 arelocated along first circumference 1181. Furthermore, seventh aperture1164 and tenth aperture 1170 are located along second circumference1183. In some embodiments, each of the apertures comprising firstcircumference 1181 (including eighth aperture 1166 and ninth aperture1168) may be disposed at a first radial distance 1187 from center 1110.In addition, in some embodiments, each of the apertures comprisingsecond circumference 1183 (seventh aperture 1164 and tenth aperture1170) may be disposed at a second radial distance 1185 from center 1110.Because center 1110 is being used as the reference point, in this case,first radial distance 1187 and second radial distance 1185 may beunderstood to refer to the approximate radius of each circumference. Asshown in FIG. 11, in some embodiments, first radial distance 1187 may beless than second radial distance 1185. In other words, each of theapertures comprising first circumference 1181 may be disposed closer tocenter 1110 than each of the apertures comprising second circumference1183. Furthermore, in one embodiment, each of the apertures comprisingfirst circumference 1181 may be disposed at substantially the sameradial distance from center 1110. In another embodiment, each of theapertures comprising second circumference 1183 may be disposed atsubstantially the same radial distance from center 1110.

Referring to FIG. 12, a first circumference 1281 comprising a first setof apertures is disposed in third pattern 1200. Generally bounding firstcircumference 1281 is a second circumference 1283 comprising a secondset of apertures. Referring to cross-sectional view 1250, it may beunderstood that twelfth aperture 1274 and thirteenth aperture 1276 arelocated along first circumference 1281. Furthermore, eleventh aperture1272 and fourteenth aperture 1278 are located along second circumference1283. In some embodiments, each of the apertures comprising firstcircumference 1281 (including twelfth aperture 1274 and thirteenthaperture 1276) may be disposed at a first radial distance 1287 fromcenter 1210. Because center 1210 is being used as the reference point,in this case, first radial distance 1287 and second radial distance 1285may be understood to refer to the approximate radius of eachcircumference. In addition, in some embodiments, each of the aperturescomprising second circumference 1283 (including eleventh aperture 1272and fourteenth aperture 1278) may be disposed at a second radialdistance 1285 from center 1210. As shown in FIG. 12, in someembodiments, first radial distance 1287 may be less than second radialdistance 1285. In other words, each of the apertures comprising firstcircumference 1281 may be disposed closer to center 1210 than each ofthe apertures comprising second circumference 1283. Furthermore, in oneembodiment, each of the apertures comprising first circumference 1281may be disposed at substantially the same radial distance from center1210. In another embodiment, each of the apertures comprising secondcircumference 1283 may be disposed at substantially the same radialdistance from center 1210.

Likewise, in FIG. 13, a first circumference 1381 comprising a first setof apertures is disposed in fourth pattern 1300. Generally boundingfirst circumference 1381 is a second circumference 1383 comprising asecond set of apertures. Referring to cross-sectional view 1350, it maybe understood that twelfth aperture 1374 and thirteenth aperture 1376are located along first circumference 1381. Furthermore, eleventhaperture 1372 and fourteenth aperture 1378 are located along secondcircumference 1383. In some embodiments, each of the aperturescomprising first circumference 1381 (including twelfth aperture 1374 andthirteenth aperture 1376) may be disposed at a first radial distance1387 from center 1310. In addition, in some embodiments, each of theapertures comprising second circumference 1383 (including eleventhaperture 1372 and fourteenth aperture 1378) may be disposed at a secondradial distance 1385 from center 1310. Because center 1310 is being usedas the reference point, in this case, first radial distance 1387 andsecond radial distance 1385 may be understood to refer to theapproximate radius of each circumference. As shown in FIG. 13, in someembodiments, first radial distance 1387 may be less than second radialdistance 1385. In other words, each of the apertures comprising firstcircumference 1381 may be disposed closer to center 1310 than each ofthe apertures comprising second circumference 1383. Furthermore, in oneembodiment, each of the apertures comprising first circumference 1381may be disposed at substantially the same radial distance from center1310. In another embodiment, each of the apertures comprising secondcircumference 1383 may be disposed at substantially the same radialdistance from center 1310.

In different embodiments, each of the circumferential arrangements ofapertures included in a pattern may be similarly disposed throughout thepattern. Thus, each circumference of apertures in first pattern 1000,second pattern 1100, third pattern 1200, and/or fourth pattern 1300 mayinclude a series of apertures that are each disposed at a substantiallysimilar radial distance from the center of the pattern.

As noted above, in different embodiments, a specific pattern may beselected and/or formed in the cushioning elements. In other embodiments,a plurality of apertures may be used and disposed in either a regular orirregular pattern along a portion of a cushioning element. In someembodiments, the apertures can be disposed over irregular intervals. Forpurposes of this disclosure, an irregular pattern refers to a generallyinconsistent (or otherwise generally varying, nonrepeating, or random)arrangement of apertures. For example, a plurality of openings that aredisposed in a generally random pattern or irregular shape may beirregularly arranged. It should be understood that some patterns mayinclude both regular patterns and irregular patterns.

A few examples of irregular patterns that may be formed are depicted inFIGS. 14-19. It should be understood that these patterns are forillustrative purposes only, and any other pattern may be formed usingthe principles disclosed herein. In FIGS. 14-18, an irregular fifthpattern (“fifth pattern”) 1400 is shown. It should be understood that inother embodiments there may be a greater or lesser number of aperturesdisposed in fifth pattern 1400 than shown here. Also, as noted above, itshould be understood that the pattern depicted in fifth pattern 1400 mayinclude apertures 150 of various shapes and/or dimensions. Thus,apertures 150 may be round or another regular or irregular shape.Furthermore, as described with reference to FIGS. 10-13, apertures 150may comprise different lengths or have substantially similar lengthsthroughout fifth pattern 1400.

In different embodiments, the apertures in a pattern can be arranged toform various smaller configurations or subsets of apertures. In someembodiments, apertures 150 may be arranged in such a manner as to formone or more curved configurations. In one embodiment, apertures 150 canbe disposed along a generally semi-circular shape, forming semi-circlearrangements. Referring to FIGS. 14-18, in some cases, one or moresemi-circles of apertures, referred to hereafter as “semi-circles,” maybe disposed around a center 1410. In some embodiments, a pattern may beformed using one or more semi-circles.

In order to better represent the various arrangements of apertures 150of fifth pattern 1400, a sequence of figures highlighting variousportions of fifth pattern 1400 are depicted in FIGS. 14-18. For purposesof this disclosure, the term “highlighted” refers to the depiction ofsome apertures as darker relative to non-highlighted apertures in theillustrations. The difference in darkness or shading of the aperturesshown in FIGS. 14-18 should thus not be taken to necessarilydifferentiate the apertures other than as identifying specific areas forpurposes of reference during this discussion. To further facilitate theidentification of specific aperture arrangements, there may be a curvedline drawn over portions of the semi-circles, emphasizing thearrangement being defined.

In FIG. 14, a first semi-circle 1402 and a second semi-circle 1404 areshown highlighted. Similar to the discussion above regardingcircumferences, apertures disposed along a common semi-circle may bealigned or disposed in a manner that forms a generally round or curvedportion of a boundary. In some embodiments, apertures described as beinglocated along the same semi-circle can be understood to mean that theapertures are disposed at a similar or nearly similar radial distancefrom center 1410. In some cases, this boundary can be solid, or theboundary can be dotted, or include gaps or openings.

In FIG. 15, two additional semi-circles are highlighted, comprising athird semi-circle 1502 and a fourth semi-circle 1504, disposed radiallyadjacent to first semi-circle 1402 and second semi-circle 1404. Forpurposes of this disclosure, “radially adjacent” refers to elements orarrangements of apertures that are disposed adjacent to one another buthave generally different radial distances from center 1410. For example,the apertures of first semi-circle 1402 are disposed at an average firstradial distance 1510 from center 1410, and the apertures of thirdsemi-circle 1502 are disposed at an average second radial distance 1520from center 1410. In some embodiments, first radial distance 1510 andsecond radial distance 1520 may differ. In FIGS. 14 and 15, first radialdistance 1510 is smaller than second radial distance 1520. In otherembodiments, first radial distance 1510 may be greater than or equal tosecond radial distance 1520.

Furthermore, in some embodiments, radially adjacent semi-circles can bearranged in a staggered or rotated configuration relative to oneanother. In the embodiment of FIG. 14-18, for example, first semi-circle1402 and fourth semi-circle 1504 are staggered relative to each other.The degree of staggering or rotation may vary in different embodiments.For example, in some embodiments, semi-circles or other aperturearrangements can form an angle less than 90 and greater than 0 degreeswith respect to one another. In other embodiments, semi-circles or otherarrangements of apertures may form an angle of 90 degrees or greaterwith respect to one another. In FIG. 15, it can be seen that firstsemi-circle 1402 and fourth semi-circle 1504 are staggered approximately90 degrees. However, in other embodiments, radially adjacentsemi-circles may be disposed in a stacked configuration, such that theaperture arrangements are generally aligned with one another (see therepeating circumferences of FIGS. 10-13).

In FIG. 16, 12 additional semi-circles are highlighted, comprising afifth semi-circle 1602, a sixth semi-circle 1604, a seventh semi-circle1606, an eighth semi-circle 1608, a ninth semi-circle 1610, a tenthsemi-circle 1612, an eleventh semi-circle 1614, a twelfth semi-circle1616, a thirteenth semi-circle 1618, a fourteenth semi-circle 1620, afifteenth semi-circle 1622, and a sixteenth semi-circle 1624. In someembodiments, semi-circles can be disposed such that they form a patternwith one another relative to center 1410. In one example, the aperturesof seventh semi-circle 1606 are disposed at an average third radialdistance 1630 from center 1410, and the apertures of eighth semi-circle1608 are disposed at an average fourth radial distance 1640 from center1410. In some embodiments, third radial distance 1630 and fourth radialdistance 1640 may be substantially similar. In other words, seventhsemi-circle 1606 and eighth semi-circle 1608 can be arranged to create apattern along a shared circumference. In one embodiment, seventhsemi-circle 1606 and eighth semi-circle 1608 can be disposed in amirrored orientation relative to center 1410. However, in otherembodiments, seventh semi-circle 1606 and eighth semi-circle 1608 can bedisposed in any position along the cushioning element. In anotherembodiment, three or more semi-circles can be oriented in repeatedpatterns around center 1410. For example, thirteenth semi-circle 1618,fourteenth semi-circle 1620, fifteenth semi-circle 1622, and sixteenthsemi-circle 1624 may be arranged in a quartered-pattern, such thatthirteenth semi-circle 1618 is disposed opposite from (mirroring)sixteenth semi-circle 1624, and fourteenth semi-circle 1620 is disposedopposite from (mirroring) fifteenth semi-circle 1622.

In addition, in some embodiments, apertures in irregular patterns mayform different shapes. For example, in FIG. 17, eight additionalsemi-circles are highlighted, as well as a first circle 1702. In someembodiments, there may be a generally discontinuous or continuous shapeformed, as in FIGS. 10-13. In FIG. 17, first circle 1702 includesapertures that are arranged to create a discontinuous boundary aroundcenter 1410, similar to the arrangement of apertures in circumferencesdescribed with reference to FIGS. 10-13.

In FIG. 18, additional apertures arranged in a variety of curved ornon-linear configurations have been highlighted, including a first outercurve 1802 and a second outer curve 1804. It should be understood thatapertures may form partial shapes or boundaries that are orienteddifferently from the semi-circles described thus far in differentembodiments. For example, in FIG. 18, first outer curve 1802 includesmultiple curved regions of apertures. Some of the curved regions maydiffer from others, as seen in a first curve 1806 and a second curve1808, which each include differently arranged apertures.

Referring again to FIGS. 14-18, in different embodiments, aperturesdisposed adjacent to one another that share a common semi-circle can bespaced apart at varying intervals or distances. For example, in FIG. 14,apertures disposed along first semi-circle 1402 are closely arrayed suchthat they contact or touch one another. Thus, the circumferentialdistance can be approximately zero. In other words, each aperture offirst semi-circle 1402 is disposed close enough to each other so as toform a substantially continuous opening similar to a siping. In anotherexample, first circumferential distance 1020 between seventeenthaperture 1084 and eighteenth aperture 1086 in FIG. 10 can beapproximately zero, such that a continuous aperture is formed.

In different embodiments, this siping facsimile can be a result of thevarying degrees of merging between adjoining apertures. In someembodiments, apertures may be formed in various portions of a cushioningelement to create a siping-like region, groove, or channel, through thecushioning element. While the arrangement can provide variations incushioning, there may be other benefits, including enhanced traction orgrip of the exterior surface. Various designs or flexible regions mayalso be formed by the inclusion of such siped apertures.

However, in other embodiments, the distance between neighboringapertures disposed along the same semi-circle can differ. In oneembodiment, referring to first circle 1702 in FIG. 17, it can be seenthat while some apertures contact one another (creating a mergedregion), other apertures in first circle 1702 are spaced apart from oneanother. For example, first circle 1702 includes a first pair and asecond pair of apertures. The apertures of the first pair are spaced ata first distance 1701 from one another, and the apertures of the secondpair are disposed at a second distance 1703 from one another. In someembodiments, first distance 1701 may differ from second distance 1703.In FIG. 17, first distance 1701 is smaller than second distance 1703. Inother embodiments, first distance 1701 may be greater than or equal tosecond distance 1703.

Thus, different pairs of apertures disposed along a shared semi-circlemay be arranged to have varying or irregular distances relative to oneanother. Similarly, the distances between apertures disposed alongdifferent semi-circles can vary. For example, referring to FIG. 15, theapertures of third semi-circle 1502 are disposed further apart than theapertures of first semi-circle 1402.

Another embodiment of a possible irregular pattern of apertures isdepicted in FIG. 19. In FIG. 19, a sixth pattern 1900 is illustrated,including a plurality of aperture rows 1950. Aperture rows 1950 mayextend various distances across sixth pattern 1900, and may comprise anyof the features, characteristics, and/or configurations described abovewith reference to FIGS. 10-18. In FIG. 19, sixth pattern 1900 includes afirst row 1902, a second row 1904, a third row 1906, and a fourth row1908. As shown in FIG. 19, in some cases, apertures may be arranged tohave generally linear configurations or designs.

In different embodiments, aperture rows 1950 may be disposed in variousconfigurations with respect to one another. In some embodiments, two ormore aperture rows 1950 may be generally parallel to one another, asdepicted in FIG. 19. In other embodiments, aperture rows 1950 may bedisposed to form different angles with respect to one another.

Furthermore, adjacent aperture rows 1950 may be arranged at variousdistances from each other. For example, there may be an average firstdistance 1910 between first row 1902 and second row 1904, and an averagesecond distance 1912 between third row 1906 and fourth row 1908. In someembodiments, first distance 1910 may be greater than second distance1912, as depicted in FIG. 19. In other embodiments, first distance 1910may be less than or equal to second distance 1912.

It should be understood that each semi-circle or aperture arrangementmay include varying numbers of apertures. Referring to FIGS. 14 and 16,for example, first semi-circle 1402 includes 12 apertures, and ninthsemi-circle 1610 includes 14 apertures. In another example, in theembodiment of FIG. 19, first row 1902 includes eight apertures, secondrow 1904 includes 14 apertures, and third row 1906 includes 15apertures. The number of apertures may be adjusted to create varyingshapes in sixth pattern 1900. In FIG. 19, sixth pattern 1900 has theapproximate (rough) shape or outline of a circle. In other embodiments,the number of apertures in any of these types of arrangements may differto include more or fewer apertures than those depicted here, and/or toapproximately form any other shape, such as square, oval, elliptical,diamond, rectangular, triangular, star, pentagonal, or any other regularor irregular shapes.

As noted above, the cushioning elements described herein may be utilizedwith various components or articles. For example, the degree ofelasticity, cushioning, and flexibility of a sole component such as asole member can be important factors associated with comfort and injuryprevention for an article of footwear. FIGS. 20-23 depict an embodimentof a method of designing a customized sole member for an article offootwear.

FIG. 20 shows the three-dimensional shape of plantar surface 2002 of afoot 2000 being measured using a data collection apparatus 2028. In somecases, data collection apparatus 2028 can be a force platform. In othercases, data collection apparatus 2028 can comprise one of thecommercially available systems for measuring plantar pressure (e.g.,Emed sensor platform, Pedar insole system, F-Scan system, Musgravefootprint system, etc.). Plantar pressure measurement systems canprovide a means of obtaining specialized information regarding a footthat can be used to customize footwear for individuals. In someembodiments, the magnitude of pressure can be determined by dividing themeasured force by the known area of the sensor or sensors evoked whilethe foot was in contact with the supporting surface in some embodiments.

For purposes of reference, foot 2000, representations of foot 2000,components associated with foot 2000 (such as an article of footwear, anupper, a sole member, a computer-aided design of foot 2000, and othercomponents/representations) may be divided into different regions. Foot2000 may include a forefoot region 2004, a midfoot region 2006 and aheel region 2008. Forefoot region 2004 may be generally associated withthe toes and joints connecting the metatarsals with the phalanges.Midfoot region 2006 may be generally associated with the metatarsals ofa foot. Heel region 2008 may be generally associated with the heel of afoot, including the calcaneus bone. In addition, foot 2000 may include alateral side 2010 and a medial side 2012. In particular, lateral side2010 and medial side 2012 may be associated with opposing sides of foot2000. Furthermore, both lateral side 2010 and medial side 2012 mayextend through forefoot region 2004, midfoot region 2006, and heelregion 2008. It will be understood that forefoot region 2004, midfootregion 2006, and heel region 2008 are only intended for purposes ofdescription and are not intended to demarcate precise regions of foot2000. Likewise, lateral side 2010 and medial side 2012 are intended torepresent generally two sides of foot 2000, rather than preciselydemarcating foot 2000 into two halves.

Furthermore, in the examples depicted in FIGS. 20 and 21, foot 2000and/or a virtual scan 2100 of a foot may include a medial arch area2020, associated with an upward curve along medial side 2012 of midfootregion 2006, and a lateral arch area 2022, associated with an upwardcurve along lateral side 2010 of midfoot region 2006. The regioncorresponding to lateral arch area 2022 is best seen in FIG. 21, whichillustrates a computer screen or virtual image of digitizedthree-dimensional foot data. As described below, the curvature of medialarch area 2020 and lateral arch area 2022 may vary from one foot toanother. In addition, foot 2000 includes a transverse arch 2024 thatextends in a direction generally aligned with lateral axis 190 nearforefoot region 2004 along plantar surface 2002. Foot 2000 also includesa heel prominence 2026, which is the prominence located in heel region2008 of foot 2000. As shown in FIG. 20, foot 2000 is illustrated as aleft foot; however, it should be understood that the followingdescription may equally apply to a mirror image of a foot or, in otherwords, a right foot.

Although the embodiments throughout this detailed description depictcomponents configured for use in athletic articles of footwear, in otherembodiments, the components may be configured to be used for variousother kinds of footwear including, but not limited to, hiking boots,soccer shoes, football shoes, sneakers, running shoes, cross-trainingshoes, rugby shoes, basketball shoes, baseball shoes as well as otherkinds of shoes. Moreover, in some embodiments, components may beconfigured for various kinds of non-sports related footwear, including,but not limited to, slippers, sandals, high-heeled footwear, loafers aswell as any other kinds of footwear.

Components associated with an article of footwear are generally made tofit various sizes of feet. In the embodiments shown, the variousarticles are configured with approximately the same footwear size. Indifferent embodiments, the components could be configured with anyfootwear sizes, including any conventional sizes for footwear known inthe art. In some embodiments, an article of footwear may be designed tofit the feet of a child. In other embodiments, an article of footwearmay be designed to fit the feet of an adult. Still, in otherembodiments, an article of footwear may be designed to fit the feet of aman or a woman.

Referring to FIGS. 20 and 21, a first step of the present method is tocollect data related to foot 2000, such as using a barefoot pressuremeasurement or other data, from the foot being measured on datacollection apparatus 2028. Data collection apparatus 2028 may includeprovisions for capturing information about an individual's feet.Specifically, in some embodiments, data collection apparatus 2028 mayinclude provisions to capture geometric information about one or morefeet. This geometric information can include size (e.g., length, width,and/or height) as well as three-dimensional information corresponding tothe customer's feet (e.g., forefoot geometry, midfoot geometry, heelgeometry, and ankle geometry). In at least one embodiment, the capturedgeometric information for a customer's foot can be used to generate athree-dimensional model of the foot for use in later stages ofmanufacturing. In particular, the customized foot information caninclude at least the width and length of the foot. In some cases, thecustomized foot information may include information about thethree-dimensional foot geometry. Customized foot information can be usedto create a three-dimensional model of the foot. Embodiments may includeany other provisions for capturing customized foot information. Thepresent embodiments could make use of any of the methods and systems forforming an upper disclosed in U.S. patent application Ser. No.14/565,582, filed Dec. 10, 2014, titled “Portable Manufacturing Systemfor Articles of Footwear,” the entirety of which is hereby incorporatedby reference.

Some embodiments could use any of the systems, devices, and methods forimaging a foot as disclosed in Leedy et al., U.S. Patent PublicationNumber 2013/0258085, published Oct. 3, 2013, and titled “Foot Imagingand Measurement Apparatus,” (previously U.S. patent application Ser. No.13/433,463, filed Mar. 29, 2012), the entirety of which is herebyincorporated by reference.

In FIG. 21, a screen 2102 displays virtual scan 2100 of plantar pressuredistributions for the foot of FIG. 20. Virtual scan 2100 may provide ameasured foot image or representation, including various distinctregions to indicate the pressures applied or experienced by foot 2000over its plantar surface 2002, as shown in FIG. 20. In one example,pressures can include a first pressure area 2104, a second pressure area2106, a third pressure area 2108, a fourth pressure area 2110, and afifth pressure area 2112. An additional pressure area 2114 is indicatedwhere plantar surface 2002 did not make an impressionable contact withthe surface of data collection apparatus 2028. In some embodiments,colors (not shown in FIG. 21) can be included in virtual scan 2100 tomore readily distinguish variations within the measured pressure data.It should be noted that in other embodiments, different, fewer, or morepressure areas may be measured or indicated.

As seen in FIG. 21, in some embodiments, the data collected may includevirtual scan 2100 of foot 2000. In some embodiments, virtual scan 2100may be used to assess the three-dimensional shape and obtain digitaldata in a two-dimensional or a three-dimensional reference frame. Inother embodiments, virtual scan 2100 can provide a baseline shape for afootwear component. In one embodiment, three-dimensional scanned imagesmay be used to measure the overall shape of a person's feet, and obtaintwo-dimensional measurements such as an outline, length, and width offoot 2000. Obtaining foot geometry can establish a baseline record forthe person in one embodiment. In some embodiments, other input may alsobe provided to supplement information regarding the person beingmeasured. In different embodiments, additional data such as toe heightinformation may also be obtained. In other embodiments, plaster casts ofa person's foot may be taken and digitized. Additionally, other digitalor imaging techniques that may be employed to capture two- andthree-dimensional foot shape and profile can be used to construct and/orsupplement virtual scan 2100. In other embodiments, the person whosefoot is being measured may provide answers to questions describing theperson's physical characteristics, limitations, preferences, and/orpersonal lifestyle, which may impact design of the various partsdescribed herein.

In different embodiments, a sole member may provide one or morefunctions for an article of footwear. In FIG. 22, an image of a templateof a sole member 2200 is displayed on a screen 2202. In someembodiments, sole member 2200 may attenuate ground reaction forces whencompressed between the foot and the ground during walking, running, orother ambulatory activities. The configuration of sole member 2200 mayvary significantly in different embodiments to include a variety ofconventional or non-conventional structures. In some cases, theconfiguration of sole member 2200 can be selected or customizedaccording to one or more types of ground surfaces on which sole member2200 may be used. Examples of ground surfaces include, but are notlimited to, natural turf, synthetic turf, dirt, as well as othersurfaces.

Upon obtaining measurements of foot 2000 (see FIG. 20), sole member 2200may be adjusted or altered in different embodiments. As seen in thevirtual representation depicted in FIG. 23, using the data collectedfrom the steps above, a first custom sole 2300 may be designed. In someembodiments, the design may utilize an application of an integratedcomputer-aided design such as a computer-automated manufacturing(CAD-CAM) process. Sole member 2200, or any other template previouslyselected, may be provided as an input to the computer design program. Inone embodiment, the three-dimensional foot shape data from virtual scan2100 in FIG. 21 is also provided to the program.

In different embodiments, virtual scan 2100 may provide informationregarding foot shape and pressure to allow the appropriate fit andcomfort within the article of footwear. The information may be used toform first custom sole 2300. In some embodiments, data from virtual scan2100 may be superimposed or otherwise incorporated into the template ofsole member 2200 (see FIGS. 21 and 22). For example, there may be aprocess of aligning the data representing the plantar pressures of foot2000 with sole member 2200 and generating a partial or complete designof first custom sole 2300. In one embodiment, pressure contour lines2306 may be generated during the design of first custom sole 2300. Thepressure distribution may be adjusted to a “best-fit” position basedupon user input in some embodiments. Once the distribution is finalized,a resiliency profile may be created. For purposes of this disclosure, aresiliency profile is a personalized pressure distribution for a userthat may include the data collected during the steps described above. Insome embodiments, the resiliency profile may be utilized in theproduction of first custom sole 2300. Thus, in one embodiment, after theresiliency profile comprising an individual's plantar pressuredistributions is aligned with the template of sole member 2200, acustomized sole member may be formed or manufactured.

It should be understood that, in different embodiments, the design of asole member may include various modifications. Customized modificationsmay provide individual users with a wider range of comfort and fit. Forexample, different users may have differences in the height of the archof foot 2000. As described above, foot 2000 may include multiple arches.Generally, the arch is a raised curve on the bottom surface of foot2000. When the tendons of foot 2000 pull a normal amount, foot 2000generally forms a moderate or normal arch. However, when tendons do notpull together properly, there may be little or no arch. This is called“flat foot” or fallen arch. Over-pronation of a foot may be common forthose with flat feet. The framework of a foot can collapse, causing thefoot to flatten and adding stress to other parts of the foot.Individuals with flat feet may need orthotics to control the flatteningof the foot. Moreover, the opposite may also occur, though high footarches are less common than flat feet. Without adequate support, highlyarched feet tend to be painful because more stress is placed on thesection of the foot between the ankle and toes. This condition can makeit difficult to fit into shoes. Individuals who have high arches usuallyneed foot support. It should be noted that such variations in archheight are one of many possible examples of customized foot geometrythat may be incorporated into a design.

Referring to FIG. 24, an embodiment of an influence diagram 2400 isdepicted. Influence diagram 2400 reflects some of the factors orvariables that can be considered, incorporated, and/or used during thegeneration of the resiliency profile, permitting customization ofcushioning characteristics 2450 of a sole member. For example, a firstfactor 2410 includes an individual's measured plantar pressure for eachfoot, which was discussed above with respect to FIGS. 20-21. Inaddition, a second factor 2420 may include the materials that will beused to form the custom sole member. Third factor 2430 can be theindividual user's own personal preferences regarding the type or levelof cushioning desired. Fourth factor 2440 may be the activity or sportthat the user will be generally engaging in while using the custom solemember. In some cases, the sole member can be designed or tailored toprovide special cushioning in areas or regions of the sole member thattypically experience more force or pressure from the foot duringspecific activities. Thus, in some embodiments, one or more of thesefactors can contribute to cushioning characteristics 2450 of a solemember. It should be understood that influence diagram 2400 is providedas an example, and many other factors not listed here may be included inother embodiments. Furthermore, one or more factors listed in influencediagram 2400 may be removed from consideration depending on the desiredoutput or the goal of the custom sole member.

Once a design has been generated, as with first custom sole 2300, thesole member may be manufactured. In some embodiments, the modificationsmay include regions of the sole member with apertures 150 disposed alongdifferent portions of the sole member. In some embodiments, a solemember can be molded in a manner that creates apertures in the solemember. An article of footwear including apertures can be formed in anymanner. In some embodiments, apertures can be created in a sole memberusing any known methods of cutting or drilling. For example, in oneembodiment, apertures can be created using laser cutting techniques.Specifically, in some cases, a laser can be used to remove material froma sole member in a manner that forms apertures in the sole member. Inanother embodiment, a hot knife process could be used for formingapertures in a sole member. Examples of methods for forming apertures ona sole member are disclosed in McDonald, U.S. Pat. No. 7,607,241, issuedOct. 27, 2009, titled “Article of Footwear with an Articulated SoleStructure,” (previously U.S. patent application Ser. No. 11/869,604,filed Oct. 9, 2007), the entirety of which is hereby incorporated byreference.

In other embodiments, however, any other type of cutting method can beused for forming apertures. Furthermore, in some cases, two or moredifferent techniques can be used for forming apertures. As an example,in another embodiment, apertures disposed on a side surface of a solemember can be formed using laser cutting, while apertures on a lowersurface of the sole member could be formed during a molding process.Still further, different types of techniques could be used according tothe material used for a sole member. For example, laser cutting may beused in cases where the sole member is made of a foam material.

In FIG. 25, a figure depicting an embodiment of a method of formingfirst custom sole 2300, including apertures, is shown. Referring to FIG.25, apertures 150 can be applied to or formed in first custom sole 2300using a laser drill 2500. In one embodiment, laser drill 2500 may beused to cut away or remove material through thickness 140 of firstcustom sole 2300. In other cases, there may be a greater number of laserdrills used. In FIG. 25, a third group of apertures 2530 along forefootregion 2004 is being formed along a surface of first custom sole 2300.First group of apertures 2510 in heel region 2008 and second group ofapertures 2520 in midfoot region 2006 are shown as having beenpreviously formed by laser drill 2500. As an example, first group ofapertures 2510 includes an arrangement substantially similar to secondpattern 1100 of FIG. 11, and second group of apertures 2520 includes anarrangement substantially similar to third pattern 1200 of FIG. 12.Furthermore, third group of apertures 2530 includes an arrangementsubstantially similar to fourth pattern 1300 of FIG. 13.

Although only apertures in one general region are shown being drilled inthis example, it will be understood that a similar method could be usedfor creating or forming apertures in any other region of first customsole 2300. It should further be understood that laser drill 2500 mayinclude provisions for moving along different directions in order todirect the laser beam to the desired location. Furthermore, the solemember may be disposed such that it may be automatically or manuallymoved to receive a laser 2570 at the appropriate or desired location,such as along forefoot region 2004, midfoot region 2006, and/or heelregion 2008. In addition, while only one laser drill 2500 is shown inuse in FIG. 25, in other embodiments, two, three, four, or more laserdrills may be engaged with the sole member.

In some embodiments, referring to a magnified area 2550, it can be seenthat laser 2570 may contact upper surface 152 of first custom sole 2300.When laser 2570 contacts the material, it may begin to remove materialand form a hole 2522. As laser 2570 continues to engage with thematerial of the sole member, hole 2522 may grow through thickness 140and form a first aperture 2560.

It may be recalled that each aperture may be formed such that theydiffer in one or more respects from one another, or they may be formedin a uniform manner, such that they are substantially similar in size,length, and shape. Furthermore, it should be understood that laser 2500may be oriented at an angle different from that shown in FIG. 25, sothat laser 2500 can form apertures 150 oriented in a diagonal ornon-parallel manner with respect to vertical axis 170, longitudinal axis180, and/or lateral axis 190.

Thus, as described herein, in some embodiments, the arrangement ofapertures on a sole member could be varied to tune properties of thesole member for specific types of physical or personal characteristics,and/or athletic activities, and to provide a particular local cushioningcharacteristic. For example, in some cases, the arrangement of apertureson a sole member could be selected according to the type of sport forwhich the article of footwear is intended. In some embodiments, amanufacturer could vary the arrangement of apertures for various typesof footwear, including, but not limited to, soccer footwear, runningfootwear, cross-training footwear, basketball footwear, as well as othertypes of footwear. Additionally, in other embodiments, the arrangementof apertures on a sole member could be varied according to the gender ofthe intended user. For example, in some cases, the aperture arrangementsmay vary between footwear for men and footwear for women. Still further,in some embodiments, the arrangement of apertures on a sole member couldbe varied according to preferences of a user for achieving desiredperformance effects. As an example, a desire for increased flexibilityon a lateral side of the article can be accommodated by increasing thenumber and/or size of apertures on the lateral side of the sole member.In addition, in some embodiments, the configuration of apertures on asole could be varied to achieve various visual or graphical effects.Furthermore, as discussed above, the arrangement of apertures can beindividually customized by measuring various pressure regions of aperson's foot and applying that information to the positioning and typeof apertures on the sole member.

It should be understood that methods of customizing apertureconfiguration for particular sports, gender, and/or personal preferencescan be achieved in any manner. In one embodiment, a method ofcustomizing aperture configuration for an article can include provisionsfor allowing a user to select a customized aperture arrangement byinteracting with a website that provides customization tools for varyingthe number and/or geometry of various apertures. Examples of differentcustomization systems that can be used for customizing apertureconfigurations are disclosed in Allen et al., U.S. Patent PublicationNumber 2005/0071242, published Mar. 31, 2005, titled “Method and Systemfor Custom-Manufacturing Footwear,” (previously U.S. patent applicationSer. No. 10/675,237, filed Sep. 30, 2003), and Potter et al., U.S.Patent Publication Number 2004/0024645, published Feb. 5, 2004, titled“Custom Fit Sale of Footwear,” (previously U.S. patent application Ser.No. 10/099,685, filed Mar. 14, 2002) the entirety of both being herebyincorporated by reference. It will be understood that the method ofcustomizing aperture arrangements for an article of footwear are notlimited to use with any particular customization system, and in generalany type of customization system known in the art could be used.

Articles of the embodiments discussed herein may be made from materialsknown in the art for making articles of footwear. For example, a solemember may be made from any suitable material, including, but notlimited to, elastomers, siloxanes, natural rubber, other syntheticrubbers, aluminum, steel, natural leather, synthetic leather, foams, orplastics. In an exemplary embodiment, materials for a sole member can beselected to enhance the overall flexibility, fit, and stability of thearticle. In one embodiment, a foam material can be used with a solemember, as foam can provide the desired elasticity and strength. Inanother embodiment, a rubber material could be used to make a midsole ofa sole member. In still another embodiment, a thermoplastic materialcould be used with a sole member. For example, in one embodiment,thermoplastic polyurethane (TPU) may be used to make a midsole for asole member. In still other embodiments, a sole member may comprise amulti-density insert that comprises at least two regions of differingdensities. For example, in one other embodiment, a midsole of a solemember could be configured to receive one or more inserts. Examples ofdifferent types of inserts that could be used are disclosed in Yu etal., U.S. Pat. No. 7,941,938, issued May 17, 2011, titled “Article ofFootwear with Lightweight Sole Assembly,” (previously U.S. patentapplication Ser. No. 11/752,348, filed Mar. 23, 2007), the entirety ofwhich is hereby incorporated by reference. Also, an upper may be madefrom any suitable material known in the art, including, but not limitedto, nylon, natural leather, synthetic leather, natural rubber, orsynthetic rubber.

An article of footwear can include provisions for adjusting theflexibility characteristics of a sole member with a plurality ofapertures. In some embodiments, different materials can be used withdifferent portions of a sole. In an exemplary embodiment, portions of asole can be filled with additional material or components to providedifferent types of cushioning, feel, and flexibility for a sole member.For example, in one embodiment, a core portion of a sole member maycomprise a fluid-filled member, such as an air bladder. In anotherembodiment, one or more portions of a sole member could include hollowcavities capable of receiving fluid or other materials.

An article of footwear can include provisions for adjusting theflexibility characteristics of a sole structure with a plurality ofapertures. In some embodiments, different materials can be used withdifferent portions of a sole. In an exemplary embodiment, portions of asole can be filled with additional material or components to providedifferent types of cushioning, feel, and flexibility for a solestructure. For example, in one embodiment, a core portion of a solestructure may comprise a fluid-filled member, such as an air bladder. Inanother embodiment, one or more portions of a sole structure couldinclude hollow cavities capable of receiving fluid or other materials.

FIG. 26 illustrates another embodiment of a custom sole member for anarticle of footwear. In FIG. 26, an article of footwear 2600 is shown,hereby referred to as article 2600. Article 2600 can be configured asany type of footwear including, but not limited to, hiking boots, soccershoes, football shoes, sneakers, rugby shoes, basketball shoes, baseballshoes as well as other kinds of footwear. Article 2600 can comprise anupper 2602 and a sole structure 2610. Sole structure 2610 is secured toupper 2602 and extends between the foot and the ground when article 2600is worn. In different embodiments, sole structure 2610 may includedifferent components. For example, sole structure 2610 may include anoutsole, a midsole, and/or an insole. In some cases, one or more ofthese components may be optional.

Generally, a customized sole member may comprise any layer or element ofsole structure 2610, and be configured as desired. In particular, layersof the sole structure may have any design, shape, size, and/or color.For example, in embodiments where an article of footwear is a basketballshoe, a sole member could include contours shaped to provide greatersupport to heel prominence. In embodiments where the article of footwearis a running shoe, the custom sole member could be configured withcontours supporting forefoot region 2004. In some embodiments, solestructure 2610 could further include provisions for fastening to anupper or another sole layer, and may include still other provisionsfound in footwear sole members. Also, some embodiments of sole structure2610 may include other materials disposed within the custom sole member,such as air bladders, leather, synthetic materials (such as plastic orsynthetic leather), mesh, foam, or a combination thereon.

The material selected for sole structure 2610 or components of solestructure 2610 may possess sufficient durability to withstand therepetitive compressive and bending forces that are generated duringrunning or other athletic activities. In some embodiments, thematerial(s) may include foams; polymers such as urethane or nylon;resins; metals such as aluminum, titanium, stainless steel, orlightweight alloys; or composite materials that combine carbon or glassfibers with a polymer material, ABS plastics, PLA, glass-filledpolyamides, stereolithography materials (epoxy resins), silver,titanium, steel, wax, photopolymers, and polycarbonate. The customizedsole member may also be formed from a single material or a combinationof different materials. For example, one side of a custom sole membermay be formed from a polymer whereas the opposing side may be formedfrom a foam. In addition, specific regions may be formed from differentmaterials depending upon the anticipated forces experienced by eachregion.

In FIG. 26, a bottom isometric view of upper 2602 (in dotted line) withsole structure 2610 is shown, where sole structure 2610 includes asecond custom sole 2650. An upper surface 2652 is provided on the upperside of second custom sole 2650, and a lower surface 2654 is provided onthe bottom side (i.e., the side that would be facing the ground and/oran outsole when worn by a user). Together, upper surface 2652 and lowersurface 2654 comprise an exterior surface of second custom sole 2650.Disposed along various portions of the exterior surface are apertures150 that extend varying lengths and comprise varying patterns throughthickness 140 of second custom sole 2650.

In some embodiments, apertures 150 may be disposed on both upper surface2652 and lower surface 2654 of second custom sole 2650. In otherembodiments, apertures 150 may be disposed on only one surface of secondcustom sole 2650. In FIG. 26, apertures 150 are formed along lowersurface 2654. A seventh pattern 2670 is visible in heel region 2008, andan eighth pattern 2680 is visible medial in a portion of forefoot region2004. As an example, seventh pattern 2670 includes an arrangementsubstantially similar to sixth pattern 1900 of FIG. 19, and eighthpattern 2680 includes an arrangement substantially similar to fifthpattern 1400 of FIG. 14. In other embodiments, any other regular orirregular pattern may be included in second custom sole 2650.Furthermore, any of the aperture patterns described herein may beenlarged or shrunk (i.e., such that the sizes of each aperture in thepattern are increased or decreased proportionally) to includedifferent-sized patterns in a sole member. In other words, in someembodiments, a sole member may include a portion of a single patternthat is enlarged to extend over the entirety of the sole member. Inanother embodiment, a single pattern may be reduced in size tocorrespond to the big toe region of the sole member. In otherembodiments, any pattern may be resized to be formed along any portionof a sole member. In one embodiment, any of the patterns may be onlypartially formed on a sole member.

As noted above, apertures 150 may be arranged to correspond to and/orsupport the contours of plantar surface 2002 of foot 2000 (as describedabove with reference to FIGS. 20-23). Thus, second custom sole 2650 canprovide both general cushioning throughout forefoot region 2004 and heelregion 2008, as well as more specialized cushioning in regions whereapertures are disposed in particular arrangements (as discussedpreviously).

Thus, the various cushioning elements as described here can provide acustom sole structure with specialized responses to ground reactionforces. In one embodiment, the cushioning element may attenuate anddistributes ground reaction forces. For example, when a portion of thecustom sole structure contacts the ground, the apertures disposed in thecushioning element can help attenuate the ground reaction forces. Thecushioning element may have the capacity to distribute the groundreaction forces throughout a substantial portion of the custom solestructure. The attenuating property of this type of structure can reducethe degree of the effect that ground reaction forces have on the foot,and the distributive property distributes the ground reaction forces tovarious portions of a foot. In some embodiments, such features mayreduce the peak ground reaction force experienced by the foot.

In other embodiments, cushioning element designs disclosed in thisdescription may also include provisions to achieve a non-uniform groundreaction force distribution. For example, the ground reaction forcedistribution of a custom sole structure could provide a wearer with aresponse similar to that of barefoot running, but with attenuated groundreaction forces. That is, the custom sole structure could be designed toimpart the feeling of barefoot running, but with a reduced level ofground reaction forces. Additionally, in another example, the groundreaction forces could be more concentrated in the medial side of a footthan along the lateral side of the foot, thereby reducing theprobability that the foot will over-pronate, or imparting greaterresistance to eversion and inversion of the foot.

In some embodiments, the use of cushioning elements in orthotics for anarticle of footwear can help support weakened areas of a foot and assistthe user in each step. While a relatively rigid material, as may beincluded in a custom sole structure, can provide functional support tothe foot, softer or more flexible regions associated with apertures 150can absorb the loads put on the foot and provide protection. Such softeror cushioned regions can better absorb the loads placed on a foot,increase stabilization, and take pressure off uncomfortable or sorespots of the feet.

Other embodiments or variations of custom sole structures may includeother lattice structure designs or various combinations of theabove-disclosed designs. It should be noted that the present descriptionis not limited to cushioning elements having the geometry or apertureconfigurations of first custom sole 2300 or second custom sole 2650. Indifferent embodiments, each customized sole structure may includefurther variations not depicted in the figures. Some variations mayinclude differences in shape, size, contour, elevations, depressions,curvatures, and other variations. In other words, the custom solestructures depicted herein are merely intended to provide an example ofthe many types of cushioning element-based sole structure configurationsthat fall within the scope of the present discussion.

An embodiment of the sole member production process as described hereinis outlined in the flow chart of FIG. 27. In a first step 2710, apressure distribution of a user's feet is obtained (see FIGS. 20-23above). In other words, the pressure distributions associated with auser's left foot and/or a right foot (i.e., a first foot and a secondfoot) may be obtained. The pressure distributions as well as any otherpreferences are collected to generate a resiliency profile. In a secondstep 2720, the resiliency profile may be used to produce a customconfiguration or pattern of apertures (e.g., position, size, lengths,orientation, etc.) in a sole member. The particular configuration ofapertures generated may be stored in a virtual or digital form in someembodiments. It should be understood that in some embodiments, a firstpattern of apertures may be produced for a left foot, and a secondpattern of apertures may be produced for a corresponding right foot.Following the production of one or more aperture patterns, instructionsto form the apertures in a sole member may be prepared or generated in athird step 2730. In some cases, the aperture pattern may be convertedinto a series of commands or instructions for a system to follow inorder to translate the aperture pattern into mechanical or design stepsfor forming the customized sole member. Finally, in a fourth step 2740,the instructions are executed and a custom sole member is produced. Insome embodiments, the instructions may be executed to produce a firstcustom sole member (e.g., for a left foot) and a complementary secondcustom sole member (e.g., for a right foot).

The process described herein may occur in rapid succession and in closeproximity to one another in some embodiments. However, in otherembodiments, one or more steps may occur spaced apart in time andlocation. In other words, one step may occur in a first location, andanother step may occur in a second location, where the first location isdifferent from the second location. For example, the resiliency profileof first step 2710 may be produced off-site (e.g., at a shopping outletor a medial office, etc.), and the aperture pattern of second step 2720may be produced in a manufacturing facility. In another example, theinstructions for forming the apertures of third step 2730 may beprepared or generated in a local site, while the actual production ofthe custom sole member of fourth step 2740 may occur in a remote site(e.g., out of state, or abroad).

In different embodiments, sole members as well as any apertures in thesole members discussed herein may be formed using any other method knownin the art. In some embodiments, any removal process (i.e., where aportion of a material is removed, subtracted, eliminated, etc.) may beused to form one or more apertures (e.g., apertures 150). For example,in some embodiments, a mechanical process may be used, including but notlimited to ultrasonic machining, water jet machining, abrasive jetmachining, abrasive water jet machining, ice jet machining, and/ormagnetic abrasive finishing. In other embodiments, chemical processesmay be utilized, including but not limited to chemical milling,photochemical milling, and/or eletropolishing. Furthermore, in someembodiments, electrochemical processes may be used. In otherembodiments, thermal processes can be used, such as electrodischargemachining (EDM), laser beam machining, electron beam machining, plasmabeam machining, and/or ion beam machining, or other processes. Inanother embodiment, hybrid electrochemical processes can be utilized,including but not limited to electrochemical grinding, electrochemicalhoning, electrochemical superfinishing, and/or electrochemical buffing.In addition, hybrid thermal processes may be used, such aselectroerosion dissolution machining. In other embodiments, the materialcomprising the sole member may be modified using chemical processes,including temperature changes (e.g., freezing the material).Furthermore, the processes for forming the apertures may be applied orutilized after the article of footwear has been assembled, or the solemember has been associated with an upper or sole structure. In otherwords, the formation of apertures in a sole member may occurpost-manufacturing of the article of footwear.

It should be understood that in other embodiments, the midsole caninclude a casing in a molded foam. In other words, embodiments of thesole member as described herein may be associated with the midsole of asole structure. Thus, in some embodiments, a midsole may include a foammaterial. The foam material can comprise a ‘skin’ surface that is formedfrom a molding process. In some embodiments, the various removalprocesses described above (e.g., drilling, laser, chemical, EDM, watercutting, etc.) can be applied to the foam skin of a midsole andapertures can be formed in a manner similar to the embodiments discussedabove.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting, and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Although many possible combinations of features are shownin the accompanying figures and discussed in this detailed description,many other combinations of the disclosed features are possible. Anyfeature of any embodiment may be used in combination with or substitutedfor any other feature or element in any other embodiment unlessspecifically restricted. Therefore, it will be understood that any ofthe features shown and/or discussed in the present disclosure may beimplemented together in any suitable combination. Accordingly, theembodiments are not to be restricted except in light of the attachedclaims and their equivalents. Also, various modifications and changesmay be made within the scope of the attached claims.

What is claimed is:
 1. A method for customizing a cushioning sole systemfor an article of footwear, comprising: obtaining information about apressure distribution of a wearer's foot; producing a first patterncomprising a first set of apertures based on the pressure distribution;generating instructions to form the first pattern in a sole member, thesole member including: (a) an outer surface, the outer surfacecomprising an upper surface and a lower surface, and (b) an interiorportion disposed between the upper surface and the lower surface; andexecuting the instructions to form the first set of apertures in thesole member, wherein the first set of apertures is disposed along aportion of the outer surface of the sole member, wherein the first setof apertures includes more than 100 apertures formed as a plurality ofrings of apertures, with each ring of apertures in the first set ofapertures being arranged along the outer surface of the sole member in agenerally round and circular first pattern around a first center,wherein the plurality of rings of apertures includes: (a) a first ringof apertures located a first radial distance from the first center, thefirst ring of apertures having a first length into the sole member and(b) a second ring of apertures located a second radial distance from thefirst center, the second ring of apertures having a second length intothe sole member, wherein the first radial distance differs from thesecond radial distance, and wherein the first length differs from thesecond length.
 2. The method of claim 1, wherein the producing stepincludes producing a second pattern comprising a second set of aperturesbased on the pressure distribution; wherein the generating step includesgenerating instructions to form the second pattern in the sole member;wherein the executing step includes forming the second set of aperturesalong a portion of the outer surface of the sole member in a generallyround and circular second pattern; and wherein the generally round andcircular second pattern is spaced apart from the generally round andcircular first pattern.
 3. The method of claim 2, wherein apertures inthe first set of apertures are spaced apart at regular intervals aroundthe generally round and circular first pattern.
 4. The method of claim3, wherein apertures in the second set of apertures are spaced apart atregular intervals around the generally round and circular secondpattern.
 5. The method of claim 2, wherein the executing step includeslaser cutting the first set of apertures and the second set of aperturesin a foam material included as the sole member.
 6. The method of claim2, wherein the first center is located in a heel region of the solemember, and wherein the generally round and circular second pattern hasa second center located in a midfoot region of the sole member.
 7. Themethod of claim 2, wherein the first center is located in a heel regionof the sole member, and wherein the generally round and circular secondpattern has a second center located in a forefoot region of the solemember.
 8. The method of claim 2, wherein the first center is located ina midfoot region of the sole member, and wherein the generally round andcircular second pattern has a second center located in a forefoot regionof the sole member.
 9. The method of claim 2, wherein the producing stepincludes producing a third pattern comprising a third set of aperturesbased on the pressure distribution; wherein the generating step includesgenerating instructions to form the third pattern in the sole member;wherein the executing step includes forming the third set of aperturesalong a portion of the outer surface of the sole member in a generallyround and circular third pattern; and wherein the generally round andcircular third pattern is spaced apart from the generally round andcircular first pattern and from the generally round and circular secondpattern.
 10. The method of claim 9, wherein the first center is locatedin a heel region of the sole member, wherein the generally round andcircular second pattern has a second center located in a midfoot regionof the sole member, and wherein the generally round and circular thirdpattern has a third center located in a forefoot region of the solemember.
 11. The method of claim 2, wherein the second set of aperturesincludes more than 30 apertures.
 12. The method of claim 1, wherein theplurality of rings of apertures further includes a third ring ofapertures located a third radial distance from the first center, thethird ring of apertures having a third length into the sole member,wherein the third radial distance differs from the first radial distanceand the second radial distance, and wherein the third length differsfrom the first length and the second length.
 13. A method forcustomizing a cushioning sole system for an article of footwear,comprising: obtaining information about a pressure distribution of awearer's foot; producing a first pattern comprising a first set ofapertures based on the pressure distribution; generating instructions toform the first pattern in a sole member, the sole member including: (a)an outer surface, the outer surface comprising an upper surface and alower surface, and (b) an interior portion disposed between the uppersurface and the lower surface; and executing the instructions to formthe first set of apertures in the sole member, wherein the first set ofapertures is disposed along a portion of the outer surface of the solemember, wherein the first set of apertures includes more than 100apertures formed as a plurality of rings of apertures, with each ring ofapertures in the first set of apertures being arranged along the outersurface of the sole member in a generally round and circular firstpattern around a first center, wherein the plurality of rings ofapertures includes: (a) a first ring of apertures located a first radialdistance from the first center and (b) a second ring of apertureslocated a second radial distance from the first center, and wherein thefirst radial distance differs from the second radial distance.
 14. Themethod of claim 13, wherein the executing step includes cutting ordrilling the first set of apertures in a foam material included as thesole member.
 15. The method of claim 13, wherein the producing stepincludes producing a second pattern comprising a second set of aperturesbased on the pressure distribution; wherein the generating step includesgenerating instructions to form the second pattern in the sole member;wherein the executing step includes forming the second set of aperturesalong a portion of the outer surface of the sole member in a generallyround and circular second pattern; and wherein the generally round andcircular second pattern is spaced apart from the generally round andcircular first pattern.
 16. The method of claim 15, wherein apertures inthe first set of apertures are spaced apart at regular intervals aroundthe generally round and circular first pattern, and wherein apertures inthe second set of apertures are spaced apart at regular intervals aroundthe generally round and circular second pattern.
 17. The method of claim15, wherein the producing step includes producing a third patterncomprising a third set of apertures based on the pressure distribution;wherein the generating step includes generating instructions to form thethird pattern in the sole member; wherein the executing step includesforming the third set of apertures along a portion of the outer surfaceof the sole member in a generally round and circular third pattern; andwherein the generally round and circular third pattern is spaced apartfrom the generally round and circular first pattern and from thegenerally round and circular second pattern.
 18. The method of claim 13,wherein the plurality of rings of apertures further includes a thirdring of apertures located a third radial distance from the first center,and wherein the third radial distance differs from the first radialdistance and the second radial distance.
 19. The method of claim 13,wherein the producing step includes producing a second patterncomprising a second set of apertures based on the pressure distribution;wherein the generating step includes generating instructions to form thesecond pattern in the sole member; wherein the executing step includesforming the second set of apertures along a portion of the outer surfaceof the sole member; and wherein the second pattern is spaced apart fromthe first pattern.
 20. The method of claim 19, wherein the producingstep includes producing a third pattern comprising a third set ofapertures based on the pressure distribution; wherein the generatingstep includes generating instructions to form the third pattern in thesole member; wherein the executing step includes forming the third setof apertures along a portion of the outer surface of the sole member;and wherein the third pattern is spaced apart from the first pattern andfrom the second pattern.